Strategies for Global Manufacturing A European View of IMS

Session: Sustainable Manufacturing

15-16 November, ETHZ, Zurich

Lifecycle considerations for sustainable manufacturing

prof. Marco Garetti Politecnico di Milano, Italy (marco.garetti@polimi.it)
Visit the web site of the International Working Group on PLM: plm-iwg.org

What we would talk about ....

The concept of product lifecycle management Why the conventional view of PLM has to be enlarged Importance of PLM for sustainability Issues and challenges

prof. Marco Garetti

The forerunner of Product Lifecycle Management

.. not too long time ago

The friendly village cobbler knew his customers, their needs, their preferences designed the product manufactured the product sold the product repaired & maintained the product recycled the product

Problem of this model: it is not scalable !

prof. Marco Garetti

Today the situation is much more complex

DesignVa

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ch

a Manufacturing in

Collaboration Dismiss (Recycle) Distribution

Su pp

ly

ch

Se Use rv ice c ain

Repair

ha in

prof. Marco Garetti

Phases of Product Lifecycle : BoL+MoL+EoL

Every product life cycle is characterised by three phases:

Beginning of Life (BoL), including Design and Manufacturing, Middle-of-Life (MoL), including Use, Service and Maintenance and End-of-Life (EoL), characterised by different scenarios: reuse of the product with refurbishing, reuse of components with disassembly and refurbishing, disposal with or without incineration, ....
prof. Marco Garetti

What is Product Lifecycle Manageament ?

In the past, the PLM acronim has been used mainly for the BoL (design and manufacturing) phase !

CAD/CAM world
Digital product Product development process Digital manufacturing

Product design and operations need to be connected !

PLM =
Digital factory Operations & Supply Chain process Documentation management

ERP/SCM world

prof. Marco Garetti

What PLM really is : BoL, Beginning of Life

PLM has to be defined as a product centric approach, ICT supported, in which product information is shared among processes and organization in the different phases of the product life cycle for achieving top range performances and sustainability for the product and related services
-Design for X -Digital product -Digital manufacturing -Reconfiguration of production system -Efficient production logistics

Product/Part/Component life-time Status of EOL product Recycling/Reuse rate of each component Dismantling information Environmental effects information

BoL a product design support

MoL

EoL

Production status information Design knowledge

Usage data of product and machine Maintenance event data and history Failure information Technical customer support info. Updated BOM by repair Updated product requirements

(*) PLM System

(*) a system of systems

prof. Marco Garetti

What PLM really is : MoL, Middle of Life

PLM has to be defined as a product centric approach, ICT supported, in which product information is shared among processes and organization in the different phases of the product life cycle for achieving top range performances and sustainability for the product and related services
-Maintenance policies (CBM, prognostic) -MoL maintenance/service optimization - Customer care

BoL

MoL

EoL

Usage status information Product logistics information Maintenance history BOM information Info. for maintenance/service Product order information Production system configuration Recycling/Reusing part or component information

(*) PLM System (*) a system of systems

prof. Marco Garetti

a product service support

What PLM really is : EoL, End of Life

PLM has to be defined as a product centric approach, ICT supported, in which product information is shared among processes and organization in the different phases of the product life cycle for achieving top range performances and sustainability for the product and related services
-EoL product logistics/waste stream management -EoL product decision making

BoL

MoL

EoL

Usage status information Updated BOM by changing parts or components Maintenance history Disassembly information Assembly info. for remanufacturing Product information (material info., BOM, parts/components costs)

Product/Part/Component life-time Status of EoL product Recycling/Reuse rate of each component Dismantling information Environmental effects information

EU Legislation (Vehicle EoL): 85% recycling / recovery rates in terms of weight by 2006 95% recycling / recovery rates in terms of weight by 2015

(*) PLM System

a product recycling/di smis suppt

(*) a system of systems

prof. Marco Garetti

Many types of Product data

Customers specifications and feedback After sales Product Usage Product network feedback information specifications

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Components and vehicle design

Technical and users manuals

Production and assembly cycles

Costs and investments estimation Procurements and logistic

Certification

Testing

Prototype production Mass production

Adapted from PLM Systems

prof. Marco Garetti

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Need of cooperation among actors of product lifecycle

Recycling

Spare parts supplier

Design supplier

Sales Information Financial Information Test & Eval. Information QA Information

System supplier
Adapted from PLM Systems

Module supplier

Training Information

Supplier Information

Service

Components supplier
prof. Marco Garetti

The P (Product) dependance

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The lifecycle model is strongly dependent on the product type, therefore PLM models and services strongly depends on the type of product we are considering: 1) product is a complex long life manufacturing object (e.g. a car, a plane, a turbine, ..) 2) product is a complex short life manufacturing object (e.g. a PC, a CDplayer, a camera..) 3) product is a pharmaceutical specialty (e.g. a vaccine, an antibiotic, ..) 4) product is a building (a house, a flat, ..) 5) product is a fashion garment 6) product is .....

The common issue is that, through the Product Lifecycle Management approach, integrated product data management should be achieved to have the right information, at the right time, in the right place for delivering service and sustainability along the product lifecycle
prof. Marco Garetti

PLM issues: software integration

CAS

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P ro d u c t D e v e lo p m e n t
DMU

CAD

CAM

CAPP

M a n u fa c tu rin g P la n n in g

CAD

CAE

F a c to ry P la n n in g

DES

x D M (P D M , T D M , E D M , e B O M )

and a lot more.

CRM

APS

MRP

CRP

DRP

M a r k e tin g

S a le s
ERP

P r o d u c tio n

D is trib u tio n
SCM

Courtesy of M. Garetti

prof. Marco Garetti

PLM issues: interoperability

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A lot of different devices need to be integrated: - technical systems - management systems - maintenance systems - smart devices - tags, RFID, memories,
prof. Marco Garetti

PLM issues: standards

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There are many gaps to be covered to fulfill the PLM needs: no existing standard can cover the wide PLM spectrum there are various inconsistencies among existing standards (semantics, languages, ..)

SysML

PSL

SysML

STEP

ur in g

PSL

M PL

us e Pr od uc t

SCOR
Su pp

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or ga ni

dd

De tai le

De si gn

Co nc e

prof. Marco Garetti

De s ig n

Ma nu fa

pt ua l

Di sp os al

Id ea tio n

de si gn

es ign

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ly

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Enterprise services Process Product

EDI

ebXML PLCS

PLM issues: data archiving

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- Product lifecycle may be very long (> 30 years) (e.g. aircrafts, ships, turbines) - Product data could be retained for many years (e.g. inspections, traceability, .) - Product related knowledge should be maintained

The OAIS* standard

Preservation Planning

P R O D U C E R

Data Management
Descriptive Info.
queries result sets

SIP

Ingest

Archival Storage AIP

Access

orders

DIP

C O N S U M E R

Administration SIP = Submission Information Package

MANAGEMENT
* Standard ISO Open Archival Information System

AIP = Archival Information Package DIP = Dissemination Information Package

prof. Marco Garetti

PLM relevance
Novel focus on product and services
Past Future

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Core Product (Tangible Product) Tangible Product Shell Intangible Product

The extended product concept

Added Value

Design

Production

M iddle of Life

End of Life

(adapted from Brow ne et al, 1994)

Sustainability can be seen as "optimization of the product lifecycle" Global product lifecycle optimization requires product information sharing along the various phases of product life cycle !
prof. Marco Garetti

PLM issues and challenges

Open issues

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1) definition of standards 2) interoperability 3) different models of lifecycle 4) integration of software systems and tools 5) data archiving 6) how to integrate/interoperate the information dispersed/generated along the PLC?

Challenges
1) definition of a Reference Model for the Product Lifecycle Management approach to sustainability 2) definition of the various integrated services for product lifecycle support 3) role of the PLM approach in supporting product innovation 4) integration of product and product-service related methodologies in the PLC 5) implementation of innovative ICT devices for PLM (embedded, smart, wireless ..) 6) PLM as an overall approach to product sustainability (... going beyond manufacturing sustainability!)
prof. Marco Garetti

The PLM - IWG

International Working Group on PLM Aim: to develop consensus over a conceptual model of the Product Lifecycle Management approach
Dr. Peter D. Ball University of Cranfield UK Prof. Balan Gurumoorthy Indian Science Insitute Bangalore, India

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Prof. Abdelaziz BourasUniversity of Lyon France

Prof. Soonhung Han KAIST Korea

Prof. Deba Dutta University of Michigan USA

Dr. Dimitris Kiritsis Ecole Polytechnique Lausanne, Switzerlan

Prof. Marco Garetti Politecnico di Milano Italy

Mr. Frederic Picard Airbus France

Visit the web site of the International Working Group on PLM: plm-iwg.org
prof. Marco Garetti

Dr. Sergio Terzi University of Bergamo Italy

Where the PLM IWG comes from:

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IMS NoE project 2002-2004 SIG 1: PLM 2 Int. Conference on PLM Lyon, France, 2005

3 Int. Conference on PLM Bangalore, India, 2006

4th International Conference on Product Lifecycle Management

Stezzano, Italy, 11-12- 13 July 2007
www.plm-conference.org

4 Int. Conference on PLM Milano, Italy, 2007

prof. Marco Garetti

A final message

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The civilized world we are living in is made of products

- Our model of life is based on products (for living, for transportation, for health, for dressing, for eating, for ...) - Products are designed, manufactured, used, maintained, recycled, dismissed

Sustainability of our model of life can be achieved through optimization of the use of resources along the products lifecycle, while retaining quality of products and services . but optimization and quality of product related processes are strongly based on the use of information

This is the reason why the Product Lifecycle Management approach to product information sharing represents a very important tool for achieving sustainable manufacturing !
prof. Marco Garetti

Contact

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Thank you for your attention !

Contact: marco.garetti@polimi.it Visit the web site of the International Working Group on PLM: plm-iwg.org

prof. Marco Garetti