®

디지털 공정 계획 솔루션

PLM Solution RoadShow 2009

© 2009 IBM Corporation

 IBM Software Group – Product Lifecycle Management

목차

II What
What is
is Digital
Digital Manufacturing?
Manufacturing?

II
II Design-to-Build
Design-to-Build Process
Process with
with DELMIA
DELMIA

IIII
II Process
Process Engineer
Engineer Introduction
Introduction

IV
IV DELMIA
DELMIA Process
Process Engineer
Engineer Key
Key Benefits
Benefits

2
 IBM Software Group – Product Lifecycle Management

What is Digital Manufacturing?

ƒ Process planning
ƒ Factory Modeling
ƒ Visualization and Collaboration
ƒ Simulation of operations
ƒ Ergonomic and human factor analysis

Digital Manufacturing is…

“the Keyhole to the Future”

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 IBM Software Group – Product Lifecycle Management

Bringing the two together

VIRTUAL PHYSICAL
Non Tangible Assets Tangible Assets

Product & Process Knowledge Production

INTELLECTUAL
INTELLECTUAL PROPERTY
PROPERTY REAL
REAL OPERATIONS
OPERATIONS
Courtesy Dassault Aviation
- Falcon 7X
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 IBM Software Group – Product Lifecycle Management

A Seamless End-to-End Workflow

Manufacturing Concept Workstation
Layout planning Standard Time Layout
Process Planning
Measurement
Process Detailing Ergonomics
Product
Development And Process Planning
HUMAN
Validation

Manufacturing Resource Modeling

Robot
Simulation
Execution Production and Simulation
3D Work
Process Detailing
Instructions Automation Flow
And
Manufacturing Simulation
Simulation Quality Control
Control Validation
Process Planning
Engineering Material Flow
Production Simulation
Planning
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 IBM Software Group – Product Lifecycle Management

Three Distinct Domains for Digital Manufacturing

Process Process Resource

Planning
z Product Evaluation
z Process & Resource
Planning
z Time Measurement
z Layout Planning
z Line Balancing
z Cost Analysis
Detailing &
Validation
z 3D geometry based
detailing
z Assembly Sequences
z Fastener Management
z Machining Operations
z Factory/Cell Layouts
Modeling &
Simulation
z Factory Flow Simulations
z Robotic Work cell Setup and
OLP
z NC Machining
z Virtual Reality Scenarios
z Ergonomic Analysis
z Control Engineering

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 IBM Software Group – Product Lifecycle Management

목차

II What
What is
is Digital
Digital Manufacturing?
Manufacturing?

II
II Design-to-Build
Design-to-Build Process
Process with
with DELMIA
DELMIA

IIII
II Process
Process Engineer
Engineer Introduction
Introduction

IV
IV DELMIA
DELMIA Process
Process Engineer
Engineer Key
Key Benefits
Benefits

7
 IBM Software Group – Product Lifecycle Management

Design-to-Build Process in non-DELMIA Digital Manufacturing

DESIGN ERP

INÎ Tail Number EBOM

INÎ Design Requirements

Definition
MBD Explosion
(Model Views)

Design Engineers EBOM-MBOM Manufacturing Engineers

Reconciliation

OUTÎ Tail Number MBOM & Tooling/Equipment/

OUTÎ Model-Based Definition: Features, Manpower Definition, Part/Equipment Ordering,
Annotations, Tooling Definition Work Scheduling, Textual Planning
Model Views

Textual Work
•40%+ Higher Re-planning Cost Instructions
•25%+ Higher Assembly Cost
•25%+ More Assembly Errors & Rework
OUTÎ Build Aircraft, Document As-Built Record

• Risks meeting commitments PRODUCTION MRP/MES

• Competition will make this model unsustainable

INÎ Build Plans & Work

• Limits future growth through hampering innovation

Instructions
MRP/MES
• Longer Time to Production / Market
• Longer Cycle Times in Production

Workers
• Production Knowledge Undocumented
• Intellectual Property Left Untapped
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 IBM Software Group – Product Lifecycle Management

Design-to-Build Process with DELMIA Digital Manufacturing

DESIGN ERP

INÎ Design Requirements

INÎ Tail Number MBOM

Definition
Design Engineers
Production Engineers

OUTÎ Model-Based Definition: Features, OUTÎ Part / Equipment Ordering, Work

Annotations, Tooling Definition Scheduling
M
Design Data Integration: o n: MBO ard Shop Floor Integration:
i r
9 Product Structure / Metadata / at d n
e gr mbe Stan ed i 9 Assign Daily Work Orders
Configuration / Effectivity (ENOVIA) t u g c
In 9 Part / Equipment / Worker Status
9 Intellectual Property (CATIA) R P ail N din eren n)
E T clu ref sig t
9 (in rts de en
p m
Pa TIA gs qui
A
C u t i n E
INÎ Model-Based Definition: As-Designed & OUTÎ Build Aircraft, Document As-Built Record
Requirements Ro ols
9 To
MANUFACTURING ENGINEERS 9 PRODUCTION MRP/MES
OUTÎ Model-Based Planning

INÎ Build Plans & Work

Shop Floor

Instructions
Integration:
9 Model-Based
Instructions per
Work Order
ME Planners Workers

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 IBM Software Group – Product Lifecycle Management

목차

II What
What is
is Digital
Digital Manufacturing?
Manufacturing?

II
II Design-to-Build
Design-to-Build Process
Process with
with DELMIA
DELMIA

IIII
II Process
Process Engineer
Engineer Introduction
Introduction

IV
IV DELMIA
DELMIA Process
Process Engineer
Engineer Key
Key Benefits
Benefits

10
 IBM Software Group – Product Lifecycle Management

Process Engineer Position in PLM

Engineering Hub
PRODUCT (Product)

PRODUCT

Manufacturing Hub
(Product, Process, Resource)
PROCESS

V5 DPM-Assembly
V5 DELMIA Human
Process Engineer QUEST RESOURCES
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Process Engineer에 의한 Digital Process Planning

Process Engineer®
=> 생산기술 전체 영역의 디지털 공정 및 생산계획 Solution
=> 가상생산의 PPR Hub

M-BOM 및 Option 관리 Digital 환경에서 제품의 조립

체계에 의한 공정계획 및 공수
산정, 최종 생산설비 Layout
Process Planning 계획을 수행할 수 있는
Digital Manufacturing
Resource Planning Solution

Process Engineer의 주 역할
생산 전제조건 정의 (Target, Shift Model, 6
1 투자비, 부자재, 생산계획조건 등…)
자재계획 정의, 생산 Concept 및 3D Layout

2 M-BOM 정의 및 OPTION, 이력관리 7 인간공학적 작업자 계획 및 작업자 분석

3 작업 표준공수 산정 8 Cost 분석

4 공정계획, Work Plan, Process Flow 정의 9 제품, 공정, 자원 DB 관리

5 Line Balancing (Work Load 및 Automatic ) 10 공정도, 작업표준 및 문서 출력 12

 IBM Software Group – Product Lifecycle Management

Why we need Process Engineer?

제품설계지원 Solution 생산기술지원 Solution
공장 물류흐름
HUMAN
2D CAD
조립 DPA 검증
CAE 자재 Layout
설계 DMU Robot OLP, MCP, MCS
공정계획, 표준작업시간,
3D CAD 조립공법서, 작업편성표

Process Engineer
PDM Process Planning &
Product Data Management Resource management

선행제품검토, Concept Manufacturing에서 최종 Layout 설계에 이르기 까지

관련 제품, 공정, 자원을 고려하여 쉽고, 빠르고, 정확하게, 경제성을 고려한 최적의 Process
Plan 을 수립할 수 있는 시스템 지원 필요합니다.
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 IBM Software Group – Product Lifecycle Management

Integrated Environment for Digital Process Planning

AS IS TO BE
BOM 관리 PDM

Product
제품 CATIA..

SAP, Manual
Process 조립프로세스
(Excel)..

자원 CATIA..
Resource
AutoCAD
Layout
/EXCEL..
All in one
필요한 모든 Data와 시스템이
상호 유기적으로 Link 되어 있지 않다.
Æ 시간, 노력, Data 손실

현재 생산기술과 제조에서 필요한 기술검토와 문서(공법서, 작업지시서)들은 매번 Engineer의 경험과

수작업에 의해 Excel로 만들어지고 있습니다.!!
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 IBM Software Group – Product Lifecycle Management

Non-Integrated Environment for Process Planning

1
2
3

Product Viewer
Project Premises Process Definition
Product Evaluation

Time Analyses

Line Balancing Concept

Layout

Simulation

Layout
Ergonomics
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 IBM Software Group – Product Lifecycle Management

Integrated Environment for Process Planning

1
2
3

Product Viewer
Project Premises Process Definition
Product Evaluation

Time Analyses

Line Balancing Concept

Layout

Simulation

Layout
Ergonomics
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 IBM Software Group – Product Lifecycle Management

Systematic Process Planning

Process Definition
Project Premises Product Evaluation

Time Analyses
Line Balancing Integrated
Database

Simulation
Layout

Manufacturing
Ergonomics
Concept

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 IBM Software Group – Product Lifecycle Management

Digital Process Planning in Process Engineer

Process definition Process graph

Product analyses Time analyses

Premises

DELMIA
Manufacturing
Quick access to up Hub
to date data Evaluation
Manufacturing
Quick documentation Concept
Quick analyses

Line
Balancing

Simulation
Ergonomics Layout
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 IBM Software Group – Product Lifecycle Management

Process Engineer의 전체 Work Flow

Preliminary Plan

Concept M-BOM

Engineering - BOM Manufacturing - BOM

Product

Production Plan Process Plan

Process

Final M-BOM

3D – Layout Plan 2D – Manufacturing Concept

Resource

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 IBM Software Group – Product Lifecycle Management

Process Engineer User-Interface

ƒ Easily access/edit/view

– List views
– Object properties
– Process Graphs
– Time Analyses
– Product geometry
(from PDM)
– Layout
Listview
– Line Balancing lists up all objects which belong to
selected parent object

Property dialog
for a selected object

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Planning Premises ( 전제조건 )

새로운 Project 시작 시, 생산계획을 위한 경계조건(Boundary Condition) 정의

ƒ 전제 조건의 속성 Data
– 생산일정별 생산계획
– 생산공장 Site 정보
– 교대조건(Shift Model)
– Cost 목표
– Cost 비율(Cost Rates)
– 혼류생산 비율
제품 생산계획 곡선
– Target Volume
– Target Cycle Time
– ...

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 IBM Software Group – Product Lifecycle Management

Product Evaluation ( 제품 검토 )

ƒ 외부 시스템이나 소스로부터 E-BOM

Import/Update
– E.g : From VPM or PDM or
Excel File
ƒ M-BOM 생성
ƒ Product variants 관리
– By use of variant codes and
mathematically logical
expressions

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 IBM Software Group – Product Lifecycle Management

Process Definition ( 프로세스 정의 )

ƒ Process Tree 구조에서 Process 생성 및

관리 (관련 부품과 Link)
ƒ 다중의 상세 Level 단계를 가진 Process
계층 구조 정의
Drag&drop parts
ƒ Process Graph에서 Process의 우선
directly on
순위조건과 Process 순서 정의 process
ƒ Process에 제품과 설비의 쉬운 Link
(Drag & Drop 사용)

Model precedence
constraints for
processes

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 IBM Software Group – Product Lifecycle Management

DELMIA V5 Interaction

Same Data
Manufacturing Hub is the
common data source
(one common data model)

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 IBM Software Group – Product Lifecycle Management

Time Analysis

ƒ 빠르고 효과적인 표준시간 분석값 생성

– 사용 가능한 국제표준 시간분석방법 :
– MTM-I, MTM-II, Standard Data, UAS, MEK,
WF, Office tasks, Visual Inspection,…
ƒ 표준시간 Data Card를 사용한 신속하고 효과적인
시간분석
ƒ 사용자 정의 Data Card 생성
ƒ Process 시간을 계산하기 위한 사용자 정의
함수(Formulas) 생성
ƒ 정확성을 위한 Rules Check
ƒ 유연한 검색 기능(Filtering)

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 IBM Software Group – Product Lifecycle Management

Line Balancing

ƒ PROCESS ENGINEER에서 2가지의 line balancing

module을 제공합니다.

– Work Load Balancing module

• 일반적 Line Balancing
• 신속한 Process의 Balancing
• Station/작업자 편성율(가동율) 최적화

– Automatic Line Balancing module

• 다양한 제약 구속조건 고려
• 혼류생산과 자재면적 Balancing

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 IBM Software Group – Product Lifecycle Management

From the Manufacturing Concept...

기간별 생산계획조건에 따른 생산 능력 검증 목표 Cost 추적

다른 시나리오 조건의
Manufacturing Concept과 비교

Traffic light evaluation

of Occupancy levels

3D layout 생성

사용자 작업표준서,
Simulate material flow
공정계획서 출력

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Layout
ƒ Manufacturing Concept에 의한 직접적,
Manufacturing
대략적 상세 3D Layout 생성
Concept
ƒ Line Balancing된 Resource Tree
구조와 Link
ƒ BOR(Bill of Resources) 자동 생성
ƒ 공구, 지그, 설비들에 대한 공용 System
Library 활용 다중 Layout에서 재사용
Line Balancing
resource structure

Library

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 IBM Software Group – Product Lifecycle Management

Ergonomic Evaluation

ƒ 3D 작업장에서의 정적 작업자에 의한 작업
환경평가
– human models of different
nationalities and size
(5th, 5th,95th percentil)
– View reach ranges, field of
vision
ƒ Assess workplace by using common
check sheets and analysis methods
– NIOSH, REFA, DIN, EN, etc.
– Analysis & check sheets are
stored with each workplace
and can be accessed anytime

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Reporting in Process Engineer

ƒ Process Engineer는 내장된 template editor를 이용하여 각 회사에서
요구되어지는 문서 표준에 맞추어 프린트 기능을 제공

– Combine any geometry

and meta data from
product, process and
resource on a single
template
– Print documents, or
output to
• MS Office,
Work plans, • html, xml, pdf, etc.
Cost sheets,
Station resource lists,
…

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Summary Process Planning

Output Result
ƒ Integrated Process Modeling Assembly
(Common Data Model) Simulation
Pre-Planning
ƒ MBOM Standard
Times
ƒ Task sequencing
Process
ƒ Reconcile EBOM-MBOM, & Graph
Process Plans
ƒ Status reports Bill of
Resources
ƒ Cost Tracking Target
Costing Operations
ƒ Capture and Reuse Best Balancing
Practices Work Plan

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 IBM Software Group – Product Lifecycle Management

목차

II What
What is
is Digital
Digital Manufacturing?
Manufacturing?

II
II Design-to-Build
Design-to-Build Process
Process with
with DELMIA
DELMIA

IIII
II Process
Process Engineer
Engineer Introduction
Introduction

IV
IV DELMIA
DELMIA Process
Process Engineer
Engineer Key
Key Benefits
Benefits

32
 IBM Software Group – Product Lifecycle Management

DELMIA Process Engineer Key Benefits

ƒ 체계적 방법론에 의한 생산준비 계획업무의 Structure화

ƒ Planning Process안에 모든 기술요소의 통합화
ƒ 선행단계에서 Process의 위험 및 Error요소의 검출
ƒ 검증된 공정과 자원의 재 사용
ƒ 다양하게 분산된 공정지식의 통합 사용
ƒ 시나리오를 기반한 선행단계에서의 대안평가
ƒ 체계적인 Cost Input 평가에 의한 최적 Solution의 실현
ƒ 합리적이고 이해하기 쉬운 의사결정과 변경
ƒ 중복업무의 감소
ƒ 계획의 질과 신뢰성 증진
ƒ 계획시간의 단축 (생산준비시간의 단축)
ƒ Process Planning, Detailing and Validating에 대한 연속되고 통합된 3D 환경 제공
ƒ Product Process Resource 정보를 공유하고 활용하는 Collaborative Workspace 제공

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감사합니다.

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