delmia v5 automation platform - merging digital manufacturing with automation(2)

By ARC Advisory Group

ARC WHITE PAPER

FEBRUARY 2006

DELMIA V5 Automation Platform: Merging Digital Manufacturing with Automation

Executive Overview ..................................................................3

Digital Manufacturing Comes of Age ............................................4

Design/Build: From Digital Mockup to Virtual Manufacturing ..........6

DELMIA Automation Merges Simulation with Controls ....................8

DELMIA Automation: Enabling Time-to-Market Breakthrough........ 12

Digital Manufacturing Enables Asset Management ....................... 15

PAC and Digital Manufacturing Make Good Technology Partners .... 16

Conclusions and Recommendations ........................................... 18

THOUGHT LEADERS FOR MANUFACTURING & SUPPLY CHAIN

ARC White Paper • February 2006

2 • Copyright © ARC Advisory Group • ARCweb.com

Digital Manufacturing Merges the Virtual and Physical World

External

Design

Support

Business

Customers

Production Systems

Automation

SuppliersPLM/D

CRMSRM

PLM/S

ERP

Internal

Digital Mfg

Virtual Simulation

External

Design

Support

Business

Customers

Production Systems

AutomationAutomation

SuppliersPLM/DPLM/D

CRMCRMSRMSRM

PLM/SPLM/S

ERPERP

Internal

Digital Mfg

Virtual SimulationVirtual Simulation

Digital Manufacturing’s Position in the ARC Collaborative Manufacturing Management Model


Copyright © ARC Advisory Group • ARCweb.com • 3

Along with the need for constant

innovation, manufacturers continue

to focus on reducing the cost and

time for producing the product, the

single most significant means of

remaining competitive.

Executive Overview

To even the most casual observer it is clear that manufacturing across all industrial sectors is being driven by a new set of business imperatives. Ag-ile response to volatile markets, drastic reduction of time to market, and high product variability are just some of the challenges facing manufactur-ers. Along with the need for constant innovation, manufacturers continue to focus on reducing the cost and time for producing the product, one of the single most effect means of remaining competitive. Moreover, reducing the

time for product launch while optimizing manu-facturing processes, will become even more significant as product lifecycle become shorter, product models and variants multiply, market prices erode, and out-sourcing increases.

In order to meet the demands of the new manufactur-ing paradigm, manufacturers are adopting the next-

generation of Digital Manufacturing tools like the Dassault Systemes DELMIA V5 platform. This manufacturing solution set represents an inte-grated suite of tools that provide manufacturing process design, tool and fixture design, factory and production systems design, visualization, and automation through powerful 3D virtual simulation tools. This allows the manufacturing engineer to design, synchronize, and validate production lines, robotic workcells, machine centers, production equipment, and con-trol systems completely prior to the purchase, installation, and commissioning of a single piece of physical equipment. The immediate effect and benefit for the manufacturer is a substantial reduction to the manufacturing lifecycle in time to product launch and significant cost sav-ings realized by the virtual validation and commission of production systems.

The Dassault Systemes DELMIA V5 platform encompasses and delivers tools to address all of the functional areas of the manufacturing/build do-main described. Additionally, it works in concert with the entire Dassault Systemes V5 PLM suite of CATIA product authoring, ENOVIA for manag-ing the entire design/build/support environment, and SMARTEAM for collaboration across all domains within the enterprise.

Within the Dassault Systemes DELMIA V5 platform is DELMIA Automa-tion, a new product which was released in late 2005, and includes a set of



Digital Manufacturing has arrived as

a technology and discipline within

PLM that provides a strategic

approach for the development and

implementation of manufacturing

process optimization

tools and applications that now enables the manufacturing and control en-gineer to merge the virtual production lines, workcells, robots, and other production equipment with automation and controls by generating actual control code and enabling complete validation of all control functionality and interface. DELMIA Automation provides the final step from complete simulation of the virtual factory to the real world of machine control and automated assembly. This represents a major transformation in how a manufacturer is able to design, validate, commission, and operate their production automation equipment. DELMIA Automation goes beyond the boundaries of concurrent engineering and enables complete simulation and validation of the production automation environment before a single piece of physical equipment is put into place.

Digital Manufacturing Comes of Age

When examining the current PLM market it becomes clear that providers like Dassault Systemes now offer a portfolio of design/build/support ap-plications that extend across a much broader range of the product lifecycle

than ever before. Today, the PLM solution set not only includes a mature collaborative product design do-main, but has expanded to encompass design and management of the manufacturing processes and Digi-tal Manufacturing, the latter representing a strategic and important milestone in the evolution of PLM. Digital Manufacturing has arrived as a technology and

discipline within PLM that provides a comprehensive approach for the de-velopment, implementation, and validation of all elements of the manufacturing process, which will prove to be one of the primary competi-tive differentiators for manufacturers.

Digital Manufacturing: Integration of Product Design with

Manufacturing Processes

When product authoring systems matured to the point of being able to ren-der a 3D fully digitized definition of the parts and assemblies that comprised a 100 percent digitally generated product, manufacturers had crossed a major threshold. The next major step in this evolution of PLM was to fully integrate the manufacturing processes with the product design. The concept of Digital Manufacturing begins with the design of the manu-



facturing processes, and then manages the manufacturing process informa-tion and supports effective collaboration between design and manufacturing engineering by sharing access to common digital product definition. Additionally, Digital Manufacturing represents an integrated suite of solutions that supports manufacturing process design, tool design,

and visualization through powerful virtual simulation tools that allow the manufacturing engineer to validate and optimize the manufac-turing processes.

Today, this concept is being accomplished by the use of integrated tool suites such as DELMIA V5 that are capable of generating powerful simula-tion, visualization, and other applications that can generate a virtual manufacturing world of production lines, work cells, machines, tooling, and other equipment. The digital product design is then placed in this virtual environment in or-der to integrate the product design with the build process. This offers the manufacturer the

ability to simulate entire the production process, along with the validation of these processes before the assembly lines are built, the machines and equipment are purchased and deployed, and resources are allocated.

The integration of Digital Manufacturing into PLM solutions is providing the critical link between design and manufacturing engineering, and ena-bling the collaborative environment that is so essential to successful execution of concurrent engineering practices. PLM suppliers have devel-oped and are offering digital manufacturing solutions as key components of their overall PLM strategy.

New Manufacturing Process Design Tools Redefine Concurrent

Engineering

The concept of concurrent development of both the product and the process to produce the product was introduced with concurrent engineering. It was based on the notion of designing a part not only to meet fit, form, and functional criteria, but also designing to meet manufacturability require-ments. The idea was to foster a design environment that involved collaboration between the design engineer and manufacturing engineer early in the design process. While this concept worked well for designing

Integration of Product Design with Manufacturing Processes

Generative Process Planning

Material and Work Flow Planning

Assembly Definition, Ergonomics, and Sequencing

Process Design for Production Line, Workcells, and Machines through Simulation

Process Improvement Metrics and Reporting

Work Instructions and Shop Floor Documentation

Process Optimization Modeling

Automatic Generation of Controls Logic



parts, assemblies, and even installations, there remained a fundamental disconnect between the design process and the complex set of manufactur-ing processes.

Design/Build developments are typically two distinct but related devel-opment organizations. Concept and product engineering are primarily concerned with development of a product, and manufacturing engineering is primarily concerned with development of the process to produce the product. From a software perspective, CAD/CAE tools are employed to help define "what" is to be built and manufacturing process design tools are used to help define "how" it is to be built.

Today’s next generation Digital Manufacturing and process design tools like Dassault Systemes’ DELMIA V5 enable the product design to be integrated with the manufacturing processes. This allows manufacturing engineers to create a virtual manufacturing environment through powerful simulation applications that can develop plant layouts, production lines, work cells, ma-terial and work flows, automation designs, and all manner of production processes. Just as concurrent engineering delivered a product design that allowed manufacturability, DELMIA V5, by simulating the manufacturing processes of virtual products in virtual production environments early in the product design process, allows for a better product design while optimizing the production processes. Manufacturing engineers are able to generate process plans, work steps, work flow, assembly definition and sequencing, tool design, and even generate control code. Moreover, the cost savings gen-erated are significant and immediate due to more efficient use of manufacturing assets and reduced production cycle times.

In essence, the concept of Digital Manufacturing facilitates the holistic view of product and process design as integral components of the overall prod-uct life cycle and enables product design methods to be not only be sensitive to process constraints and capabilities, but, in fact, be completely integrated with the manufacturing processes.

Design/Build: From Digital Mockup to Virtual Manufacturing

The emergence of Digital Manufacturing tools is directly linked with the evolution of PLM and the digital definition of products and processes. As



At the heart of Digital Manufacturing

are powerful next-generation 3D

simulation applications that enable the

manufacturing engineer to virtually

simulate exact models of machines,

robots, conveyor lines, workcells, and

specific production equipment.

manufacturers made the leap from paper drawings to 2D, and subsequently to 3D wire frame, solids, and fully digitized mockups of the assembled product, the technology and tools that made this possible has steadily pro-gress in scope, capability, and sophistication. At the heart of Digital

Manufacturing are powerful next-generation 3D simulation applications that enable the manufactur-ing engineer to virtually simulate exact models of machines, robots, conveyor lines, workcells, and specific production equipment required to fabri-cate, assemble, and install parts, sub-assemblies, and components of the product. Additionally, the actual factory environment of the production proc-

ess can be modeled including buildings, production lines, transportation, workflow, and other facilities that represent the complete physical produc-tion environment.

In earlier versions of PLM tools, CAD digital designs were integrated with CAM applications to enable the fabrication of machine parts. CAM tools enabled virtual cutters to be driven over digitally rendered part surfaces that would eventually be converted to machine code that CNC controllers used to drive physical cutters to machine parts. This Numerical Control (NC) function is now a standard module within most PLM solutions sets today.

Along with the CAM functionality of NC came the first simulation tools to virtually model the machine parts fabrication process. These were applica-tions that a manufacturing engineer and NC programmer could use to build virtual models of the machine tool, work piece, and cutter to simulate the motion of the machine, removal of material, and check for interference and collisions. These CAM simulations tools were the forerunners of the powerful simulation tools used today in Digital Manufacturing.

Digital Mockup for the Manufacturing Processes

Just as in product design where digital mockup tools allow the design en-gineer to develop virtual mockups of the product that would enable them to visualize the assembly of various parts, sub-assemblies and installations, so do digital manufacturing tools allow the manufacturing engineer to visualize the production processes.

With a digital mockup the design engineer is able to simulate mating sur-faces, fastening constraints, component assembly, interference points, and



even mechanical movement to determine clash points with adjoining struc-ture. By simulating the actual product to be produced, many design mistakes are avoided and product improvements made. Moreover, consid-

erable time, expense, and labor are re-duced by eliminating many of the physical prototypes that are required to validate product design in a physical state.

The entire notion of validation through digital simulation can now be applied to manufacturing processes. Digital Manu-facturing now extends visualization and virtual modeling beyond the product into the production processes and factory floor automaton systems providing not only a simulated representation, but affording the

ability for validation of production equipment and controls before the fac-tory or production line ever exists. Additionally, Lean Manufacturing and Six Sigma principles and methodologies can be incorporated and validated into the production processes to further optimize production systems.

These Digital Manufacturing concepts can also be applied down to the de-tailed level of work processes that would include tooling and fixture positioning and alignment, welding paths, fastening sequences, and even ergonomic considerations for operators and assembly workers. In essence, with this technology it is possible to simulate the entire manufacturing en-vironment, but clearly the overwhelming benefit to manufacturing operations is that all of this can be accomplished in advance of any physical implementation of production systems.

DELMIA Automation Merges Simulation with Controls

In the virtual 3D world created by the PLM technologies of solid model product authoring, digital mockup, and manufacturing process simulation, the final link to the actual production work environment is making the connection to machine control systems. It is one thing to simulate the ma-chine tool, conveyor line, robotic work cell, PLC, clamping fixture, motors,

DELMIA V5 Virtual Workcell



drives, pneumatics and hydraulics systems; but quite another exercise to generate accurate information that is capable of driving control systems for all of this production equipment. This merging of Digital Manufacturing with automation is exactly where tools such as the DELMIA V5 Automa-tion Platform are taking manufacturing in this final link to the factory floor.

Examining the Capabilities of the DELMIA V5 Automation

Platform

Today, automation systems and the controllers integral to this process such as Programmable Logic Controllers (PLCs) are programmed through a time consuming 2D graphical representation environment based on one of the IEC 6-1131-3 programming languages and each automation supplier’s pro-prietary control mapping of this control logic standard. Moreover, after the

DES

IGN

DELMIA AutomationControl Studio

Virtual Controller

VirtualHMI

DELMIA AutomationSmart Device Builder

DELMIA AutomationControlled System Simulator

VIRTUAL

“Control Design in Context”

Multi-

CAD

VA

LID

ATE

OPC ServerOPC client

PHYSICAL

OPC SERVER

Real or Soft PLC Real HMI

DELMIA AutomationPLC Setup

Developed with or by PLC providers

Multi-PLC

DES

IGN

DELMIA AutomationControl Studio

Virtual Controller

VirtualHMI

DELMIA AutomationSmart Device Builder

DELMIA AutomationControlled System Simulator

VIRTUAL

“Control Design in Context”

Multi-

CAD

VA

LID

ATE

OPC ServerOPC client

PHYSICAL

OPC SERVER

Real or Soft PLC Real HMI

DELMIA AutomationPLC Setup

Developed with or by PLC providers

Multi-PLC

DELMIA V5 Automation Platform

control logic is programmed for an automated production system, it is nec-essary for the control engineer to physically validate the controls logic within the implemented automation system. DELMIA V5 Automation in-tegrates this process into the DELMIA V5 3D environment, enabling manufacturing and control engineers to develop and validate their PLC program, along with the logic and motion control of the automated system, in a completely virtual environment.



Within the V5 3D digital environment DELMIA Automation provides a col-laborative workspace for mechanical design, manufacturing, tooling, and control engineers to share knowledge, exchange system features and attrib-utes, integrate domain process information, and react to engineering change and version updates. In the ramp-up of production lines to com-missioning and product launch, as well as the design/build process of the machine tool and packaging machine OEMs, cost, time, design changes, and risk of errors become critical factors in product delivery and ultimately profit or loss. What DELMIA Automation offers to the participants in this process is the ability to reduce errors, validate control systems, and mitigate risks in a virtual environment well before using real equipment to accom-plish commissioning. This truly represents the merging of the 3D virtual simulation environment with the physical automation world of control logic and the control platforms that perform the production processes.

The DELMIA V5 Automation Platform is comprised of several modules that take the automated system from design to development to commis-sioning. The process begins with the Smart Device Builder. This module uses existing 3D CAD models (CATIA, Solidworks, UGS NX, ProE, Solid-edge, and others) to represent actuators, sensors, motors, and drives that will actually define kinematic motion, internal logic, and electrical I/Os. Once these smart devices are created they can be assembled to build the virtual automated system complete with a set of I/Os.

Smart Device

Geometry KinematicsControl Logic &

I/Os

Smart DeviceGeometry Kinematics

Control Logic & I/Os

DELMIA Automation Smart Device

• A Smart Device can be as simple as single fixture clamp or as complex as robotic workcell, machining center, or an entire production line.

• Smart Devices can be driven by an external controller such as a PLC.



• Smart Device Builder provides the control engineer with the capability to create a virtual library of Smart Device control logic for reuse pur-poses. This is essential to manufacturers for knowledge capture of manufacturing processes.

The second module of the DELMIA V5 Automation Platform is the LCM Studio. The LCM Studio is a PLC programming environment that uses the standard IEC 6-1131-3 programming languages such as Ladder Logic or Function Blocks. LCM Studio produces a generic PLC program that is in-dependent of the PLC hardware platform. The generated control logic code is targeted to a specific PLC by running the generic control code through the LCM Control Setup module (an optional add-on to the Automation Platform) which post-processes or maps the control logic to the targeted PLC platform. The LCM Studio provides the control engineer with struc-tured views of the control logic that include hierarchal and Sequential Function Chart (SFC) views. There is also the capability to program and validate control logic in the “context” of the virtual equipment designed using Smart Device Builder.

The third module is the Controlled System Simulator, which allows the user to simulate, debug, and validate a complete PLC program against vir-tual equipment prior to any real equipment being deployed. This module represents one of the real value propositions of the DELMIA V5 Automa-tion Platform in that the manufacturer is able to dramatically reduce the development, validation, and commissioning time cycle for their produc-tion systems. Reducing the time and cost of product launch is one of the most critical factors for companies today, where hitting the market window for their product can often make the difference between success and failure.

• A PLC program can be simulated using either a virtual controller or a physical PLC using open connectivity such as OPC.

• All aspects of the PLC control logic can be validated, including I/O setup, tag values, functions, program branching, etc.

• The Controlled System Simulator can perform DMU verification of mo-tion simulations using clash detection and analysis, sectioning analysis, measurement, distance analysis, and 3D comparison tools.

The LCM Control Setup is an optional add-on that provides the user with capability to translate (post-process) control logic created with the LCM Studio to a PLC’s native logic language. LCM Control Setup provides Das-



sault Systemes CAA Partners with APIs necessary to target to specific PLCs (Siemens S7, Schneider, Omron), and allows control and maintenance engi-neers to work in the same environment as the PLC they are using.

Another optional module is the HMI Control Panel Design, which is used with the Smart Device Builder, LCM Studio, and Controlled System Simu-lator to provide the user with the capability to create a virtual HMI panel. The user is able to map virtual equipment and real PLCs and HMI panels using standards such as OPC client/server interfaces. Virtual HMI/PLC interfaces are created and translated to real OPC servers in the physical PLCs, and real HMI and dashboard clients.

DELMIA Automation: Enabling Time-to-Market Breakthrough

The maturity of PLM design/build solutions is quite evident in the automo-tive industry. Car makers were one of the first industries, along with aerospace, to adopt digital design (CAD) and digital manufacturing (CAM) technologies. Today, with the integration of product design and manufac-turing processes manifested in the emergence of Digital Manufacturing, the automotive companies again appear to be the early adopters of this tech-nology and stand to benefit significantly. In their quest to continually reduce time-to-market from concept to product launch, the car companies can depend on products like DELMIA to achieve this goal.

Driving Down the Cost of Automotive Production

The Automotive sector is indicative of an industry that is adopting Ag-ile/Flexible manufacturing methods in order to remain competitive and drive down the cost of producing their product. Companies like GM and DaimlerChrysler are introducing new models targeted to niche markets resulting in very limited production runs (20-30K) that require timely and efficient model launches if the car maker is going to realize any profit. Pro-duction lines, Workcells, and control systems must be designed, installed, and deployed in the shortest possible time and, even more importantly, work correctly with the least amount of test and validation. Digital Manu-facturing tools to virtually design and test production lines will be essential in designing and implementing these agile production systems.



Timely and Efficient Model Launches Are the Goal

While an on-demand business model for the automotive companies has direct impact on many aspects of the product lifecycle from product design to manufacturing process optimization, the structure and approach to the model launch represents an activity that will significantly affect the success and profitability of the new model. In order to respond to projected short model runs and already abbreviated production lifecycles, the production lines that are comprised of control systems, conveyors, robotics, welding and fastening systems, paint systems, metal forming and stamping, and factory networking infrastructure must be designed, installed, and commis-sioned in a very optimized and efficient manner.

Control Engineering

3D Mechanical Design

Control Engineering

Line Building & Installation

Mechanical Design

ControlEngineering

LineBuilding

Control Eng.

Production Startup

Production Startup

Current workflow….

Workflow…with DELMIA Automation

VALIDATION

Control Engineering

3D Mechanical Design

Control Engineering

Line Building & Installation

Mechanical Design

ControlEngineering

LineBuilding

Control Eng.

Production Startup

Production Startup

Current workflow….

Workflow…with DELMIA Automation

VALIDATION

Merging Virtual Design and Automation Shortens Time to Launch

The key will be the amount of time it takes to deploy, install, and commis-sion new production lines for general assembly, paint, stamping, body-in-white, and other assembly systems, and bring all of these systems up to production rate. Additionally, these engineering organizations will have to be accountable for the engineering resources expended, whether in-house or outsourced, to accomplish the model launch. Since the goal is to reduce the cost for new model launches, both time and resources have to be con-trolled while still satisfying the requirements for the production lines and the delivery of the new vehicles on schedule.

Digital Manufacturing Tools Shorten Automotive Launch Time

Next generation Digital Manufacturing tools such as DELMIA and the V5 Automation Platform are helping the car makers meet the new model



launch challenge. Initially, automotive manufacturing engineers will be able to design the manufacturing processes, workflow, assembly and instal-lation planning, and work instructions, and essentially engineer a set of optimized production processes using DELMIA manufacturing process management tools. Next, they will be able to create the virtual production lines, robotics workcells, assembly areas, and transfer lines for body-in-white, stamping, paint, general assembly, and powertrain with DELMIA simulation. Finally, controls engineers will be able to create virtual control devices, generate control code logic, and validate the entire automated as-sembly area with DELMIA Automation. The end result will be a dramatic reduction of time and engineering resources needed to validate and com-mission new production lines for new product launches as well as supporting Lean Manufacturing and Six Sigma initiatives.

Many Industry Markets Will Benefit from Digital

Manufacturing

While the automotive sector stands to gain immediate benefits from the ap-plication of Digital Manufacturing tools, other industry verticals along with systems integrators can apply this technology to gain substantial payback. The packaging machine OEM market represents an industry that would be able to use DELMIA V5 Automation in the design and commissioning of packaging machines that support the Food & Beverage and CPG industries.

Typically, a packaging machine OEM will have to design and build a ma-chine based upon the specific requirements of the user’s product. While there is a concerted effort to employ common platforms, components, and reuse in the design, build, and commissioning of the machine, a degree of customization is always a factor in the delivering the machine. Placing the digital design model of the packaging machine in the virtual production environment that can be created by DELMIA V5 Automation and validat-ing machine functions and synchronization along with controls logic generation will significantly reduce the packaging machine lifecycle devel-opment and delivery time to the customer. Since time to market and product launch are critical to the Food & Beverage and CPG industry, in-creasing the availability of packaging machinery for new products will be a highly valued factor.



Digital Manufacturing Enables Asset Management

Today, manufacturers are placing significant emphasis of maintaining and preserving their factory floor production assets. Asset management meth-ods along with the applications and tools to support it have emerged to become one of several strategies that manufacturers are following in order to drive down the cost of producing the product. With the advent of tools like the DELMIA V5 Automation Platform, factory operations managers and maintenance engineers have the capability to define all of their produc-tion assets virtually including the interface with machines, devices, production equipment, sensors, and monitors.

Defining a Virtual Asset Management Environment

Using a tool such as DELMIA Automation, the maintenance engineer can use the Smart Device Builder module to create virtual models of production equipment. This could include everything from small devices such as sen-sors, monitors, measuring instruments, motors, actuators, and servos to entire machining centers, automated assembly tools, and complex work-cells. Using the Smart Device Builder, the user can define electrical I/O interfaces for sensors and monitors, which can then be incorporated into more complex systems to support machine condition monitoring and Over-all Equipment Effectiveness (OEE) applications. The maintenance engineer can then use the virtual asset management design simulation to build, vali-date, and commission these systems.

More complex asset management applications such as Dynamic OEE can be virtually designed and validated using DELMIA Automation. Dynamic OEE helps determine the real-time impact that the current performance of any individual piece of equipment has on the overall efficiency of the plant. Methods used to display this information include digital dashboards, which can be designed to show Key Performance Indicators, or KPIs, such as throughput or downtime. Dynamic OEE analysis and reporting tools are used to identify typical problem types, when and where they occur, and provide data such as availability, performance, and quality factors per or-der, per product, and per shift. Designing and building asset management systems with DELMIA Automation provides operations managers and en-gineers with the capability to implement these systems quickly and efficiently.



Future controller selection will be

based on factors such as adherence

to open industry standards, multi-

control discipline functionality,

technical feasibility, cost

effectiveness, ease of integration,

and maintainability.

PAC and Digital Manufacturing Make Good Technology Partners

Manufacturers will base their future controller selection on factors such as adherence to open industry standards, multi-control discipline functional-ity, technical feasibility, cost effectiveness, ease of integration, and

maintainability. More importantly, embedded systems and small footprint, industrial-strength operating sys-tems will gradually change the architecture, merging robust hardware with open control.

Adding up all these factors, and including modular architecture that mirrors applications, and the increas-ing role of software in automation solutions, leads to an

emerging role for “Open PLCs”, defined by ARC as Programmable Auto-mation Controllers, or PACs. PACs will not replace or supercede the traditional PLC, but will play a major role in plant and factory automation today and in the future. This functionality can be found as part of DELMIA’s product focus, which includes multi-control discipline solutions that merge hardware with open control, along with a complete family of product lifecycle management (PLM) solutions.

PLC Evolution to PAC

There are a variety of perspectives on what an Open PLC or PAC truly is. Some consider it a traditional PLC with open architecture software, stan-dard languages such as IEC61131-3, standard communications protocols, open APIs and tool sets to use them. Others include Slot PLCs, which are traditional PLCs in a PC compatible form factor and integrated into the PC environment. Some include SoftPLCs or other PC-based controls inte-grated into the PC environment.

PACs must also open up proprietary technologies to users and integrators for their applications, especially for machine builders and OEMs where small and smart products are required as those machines and equipment become smaller and more distributed. The concept of the PAC coupled with the manufacturing process and automation design capabilities of DELMIA can address the requirements of a collaborative manufacturing environment.



A PAC must be a controller that meets user’s needs for real-time con-trol and be flexible and configurable enough so users can customize and optimize it to meet their particular needs. In a perfect world, a PAC would be an automation system with all the components for control-ling and automating both machines and plants. All parts of the system would be designed to maximize software and hardware integration. There would be one programming and engineering tool as well as one

programming language for the complete system.

Market Needs for Integrated Controllers

The ability to directly push or pull data between the controller and the en-terprise database using open standards is a huge advantage for a PAC. Where traditional PLC products can only be controlled via proprietary pro-gramming languages, a PAC can be commanded via standard IT queries such as XML and SQL, coupled with open data transfer technology such as OPC and the web, or through the use of Java programs. This allows the controllers resources such as I/O points, registers, and motion parameters, to be monitored and/or controlled via a network connection. Use of well established open IT standards allows IT professionals’ instant access to all controller resources without learning a new language, or having to install an intermediary PC and software to process the data.

The connectivity to ERP, MES and the enterprise world is increasing de-mand for tighter integration, more information, and a higher expectation that the control system will initiate communication, update the controller at the device level in real time, and serve up information. And only automa-tion platforms which allow instant access regardless of hierarchies and software interfaces without proprietary protocols could handle this. So PACs that utilize open IT and internet/intranet standards offer the best so-lution.



Conclusions and Recommendations

It is clear that the business drivers receiving the most focus today from manufacturers are:

• Reducing the cost of producing product • Shortening the Product Launch Lifecycle • Flexible Manufacturing Systems • Common Processes and Reuse • Process Optimization • Asset Preservation and Management

Manufacturers are competing for market share in a fiercely competitive en-vironment by offering ever-expanding product lines to meet customer demands for more variability and selection, as well as maintaining product quality and delivering their product in a timely manner. This means oper-ating in an Agile/Flexible manufacturing mode where production must respond to more changeable markets, shorter product lifecycles, the need to adapt to market demand and an overall more sophisticated buyer.

Given the intense competition for market share, and the absolute necessity to get products to market in time to hit the market window for consumer acceptance, companies are looking for any competitive edge that they can leverage including the optimization of their manufacturing processes. Manufacturers now have the opportunity to use next-generation PLM tools like Digital Manufacturing to help them meet the requirements mandated by these business drivers.

Streamlining the design, validation, and commissioning of production sys-tems will be a key factor for the manufacturers in meeting requirements for cost-effective and efficient product launches, and market windows. Digital Manufacturing tools like DELMIA V5 and the Automation Platform have emerged at precisely the right time in a global manufacturing climate where accelerating time to market and implementing manufacturing proc-ess optimization will be critical to a company’s success.



Analysts: Dick Slansky, Craig Resnick

Editor: Chantal Polsonetti

Acronym Reference: For a complete list of industry acronyms, refer to our web page at www.arcweb.com/Community/terms/terms.htm

API Application Program Interface

CAD Computer Aided Design

CAM Computer Aided Manufacturing

CMM Collaborative Manufacturing

Management

CPG Consumer Packaged Goods

CPM Collaborative Production

Management

CRM Customer Relationship

Management

EAM Enterprise Asset Management

ERP Enterprise Resource Planning

HMI Human Machine Interface

IEC International Electrotechnical

Commission

MES Manufacturing Execution System

OEE Operational Equipment

Effectiveness

OEM Original Equipment Manufacturer

OLE Object Linking and Embedding

OpX Operational Excellence

OPC OLE for Process Control

PAC Programmable Automation

Controller

PLC Programmable Logic Controller

PLM Product Lifecycle Management

ROA Return on Assets

RPM Real-time Performance

Management

XML eXtensible Markup Language

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All information in this report is proprietary to and copyrighted by ARC. No part of it may be reproduced without prior permission from ARC. This research has been sponsored in part by DELMIA. However, the opinions expressed by ARC in this paper are based on ARC's independent analysis.

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