virtual factory amitom without swf

7/27/2019 Virtual Factory Amitom Without Swf

1/29

Virtual Factory

Presented By Amitom

Medi-Caps

Indore


2/29

Problem StatementVirtual Factory Program As the industry moves to a model with production being

outsourced at an increasing rate, rapid product introductionand cost efficiencies promised by the outsourcing modeldepends on quickly linking the OEMs information systemswith those of their suppliers.

However, most companies are still struggling to achieveeffective inte ration of desi n and roduction functions

within their own enterprises, a difficult task even whenmanufacturing is a captive activity. Such problems are amplified for the foundry/EMS provider,

which must be able to accept designs produced by a varietyof systems and return both product and formattedinformation back to their OEM customers.

The inefficiencies (costs and product delays) in the currentoutsource model will ultimately be passed on to thecustomer until they can be resolved through an effectiveeManufacturing environment.


3/29

Defining Virtual Factory

A virtual factory is defined as anintegrated simulation model of majorsubsystems in a factory that considers thefactory as a whole and provides an

advanced decision support capability MODELING A VIRTUAL FACTORY:

Three modeling principles:-

Model the factory before building Simulate before producing

Anticipate and solve before they occur


4/29

MODELING USING QUEST:

Queuing Discrete Event Simulation Tool

Simulating manufacturing processes for ensuring cost-effective process design

Identifying and understanding process problems and inevaluating proposals for changes to processes

Models directly emulate real-world system behaviorsthrough the distributed logics

Behaviors can be customized using Simulation ControlLanguage(SCL)

Automatic data collection and tabulation for simulationruns can be captured using Batch ControlLanguage(BCL)


5/29

LANGUAGE USED:

Virtual Reality Modeling Language (VRML)

Created by Silicon Graphics, Inc. Standard 3-D format for the distribution of virtual

worlds on the Internet

VRML is the 3D analog to HTML

VRML codes are simple, reusable and compatible withJava

Using a VRML viewer, it is possible to navigate freelythrough the scene

VRML applications can have interactive behaviors thatallow user to influence the virtual environment


6/29

VIRTUAL FACTORY SOFTWARE:

One of the software available for virtual factory is VR-Fact.VR-Fact is interactive virtual factory development softwaredeveloped as a part of a research to explore theapplications of Virtual Environments (VE) in the area ofmanufacturing automation. VR-Fact creates digital mock-up of real factory shop floor. Designers can drag and placemodular machines in the factory to study issues such as

p ant ayout, c uster ormat on an part ow ana ys s. orthe design of this shop floor the user can interactivelychoose the machines which are required to manufacture aset of parts. Furthermore, the VR walk through environmentprovides a unique tool for studying physical aspects ofmachine placements. Mathematical algorithms are used for

generating independent manufacturing cells. This approachsimultaneously identifies part families and machine groupsand is particularly useful for large and sparse matrices.


7/29

DESIGNING A VIRTUALFACTORY:

The virtual factory is a mock-up of a real factory floor

It supports the analysis and design of the logistics ofmaterial movement, process flow and controlassociated with manufacturing

Ideas/proposed changes can be modeled, analyzed and

recon gure on e compu er e ore ey are u Models provide simulation, 3D visualization andanimation of machine operations to understandcomplex behaviors

Ensuring efficiency, saving money, human capital and

avoiding errors


8/29

DIFFERENT LEVELS OF VIRTUALFACTORY:

TOP LEVEL: The top level is the factory implementationwith machines, transportation,control and schedulingmodels.

INTERMEDIATE LEVEL: The intermediate level is themachine level implementation where each machine can becontrolled and loaded with parts and appropriate codes. Insuch a model it will be ossible to "touch" the machines

control "knobs" and see actual functionality. MICRO LEVEL: the VR-Factory will integrate processsimulations such as metal chip formation with givendefinition of tool geometry, simulation of chatter, tool wearetc.

This step will also foster design for manufacturability analysisand design evaluation for a given assembly ormanufacturing process.


9/29

Some Visual Scenes from SiemensIntrntl.


10/29


11/29

UNDERSTANDING THE STRUCTUREOF VIRTUAL FACTORY:

Two approaches: -

a) Downward

b) Lateral


12/29

Description

(a) Downward:-It is initiated by a large vertically integratedcompany seeking to reduce costs associated with fixedasset and to maintain focus on key operations.Outsourcingbreaks down thecompany's vertical structure. A company that successfullyoutsource becomes economically slimmer and moreado tive. It develo s lon term relationshi with the

supplier.(b) Lateral:- In small specialized enterprises firms that is inthe interest of seeking strategic alliances, form partnershipsalong a value added chain(e.g., suppliers, manufacturersand distributors). Without acquiring the ownershipheadache, the core firms of such network can increase

profit and reduce risks. Each such core firm can benefit bymodeling the adaptively and responsiveness of a small,specialized company and the large scale economies of alarge and integrated firm.


13/29

VIRTUAL FACTORY ADVANTAGES:

Improved decision-making throughout the complete

life cycle of businesses, facilities and products Can be applied to improve

Facility sizing

Equipment layout

Material handling equipment requirements Group technology

Manufacturing design

Production scheduling

Just in time / lean manufacturing design andanalysis

BPR, TOC and strategic planning


14/29

VIRTUAL FACTORY ADVANTAGES:

Improved operations efficiency, throughput,

flexibility and profitability of the operationsmodeled

Streamline lead times

Decrease capital investment, inventories, andrisks associated with change

Can be used to analyze/perform time studies,human accessibility/ergonomics/safety,process

optimization and verification To face the future with confidence


15/29

VIRTUAL FACTORY ADVANTAGES FORSTUDENTS:

Helps engineering and business students to grasp

factory dynamics that are difficult to teach in lecturesand impossible to experiment in real factories

Allows students to work in groups to build factories,forecast demand for products, plan production,

,

and setting scheduling rules for workstations

Helps students to build a robust operatingprocedure to keep the system running smoothly

Students can program and configure the machinemodel in order to minimize the cycle time.


16/29

CHALLENGES:

The challenges facing virtual factoryare inexperienced users, security,expense control, and the level of

successful virtual factory.


17/29

Program ObjectivesVirtual Factory Program

Standardize and automate the common

business processes of contract manufacturingprocess to significantly reduce the cost andlead-time to change manufacturing capacity

an oca on. Ensure the quality of the outsourced product.

Provide visibility into the virtualmanufacturing environment.


18/29

Standardize and automate the common

business processes of contract manufacturingprocess to significantly reduce the cost andlead-time to change manufacturing capacity

an oca on. Ensure the quality of the outsourced product.

Provide visibility into the virtualmanufacturing environment.


19/29

What is Virtual Factory?Virtual Factory Program

Virtual Factory is a set of extensions tothe core Order Management processscenario framework to facilitate the

information needed to support all orpart of the outsourcing of the design

and manufacturing of a product


20/29

Process Scenario

Order Mgmt

Virtual Factory DemandCreation

Design Forecast

ProductDataMgmt

2C Factory

CapacityPlanning7B + 4A

CollaborativeDesign2D

Order

Payment

LogisticsDesign

Transfer

7A

or r er

&WIP Mgmt7B

Direct Ship& 3rd PartyFulfillment2B, 3C, 4C

ProductGenealogy& Quality

7C

VirtualManufacturing

ConsignedMaterials


21/29

Alignment Across BoardsVirtual Factory Program

Semiconduct

or

Manufacturin

g

Electronic

Components

Information

Technology

Boards

BoardSpecific

Priorities

Virtual Factory Milestone Programs

SpecificMilestone

Programs

with cross board

Validation teams

Resulting in cross

Supply Chain

Virtual Factory PIPsCommon Virtual Factory PIPs


22/29

Virtual Factory Process ModelFactory WO & WIP

Work Order and WIP

Mgmt - Enables theexchange

manufacturinginstructions that are

DemandCreation

Design Forecast

pecu ar o a wor

order. Also providesinformation about

Work In Progress. WIPPIPs have been

engineered andvalidated, WO PIPs

have not been definedyet.

Order

ManufacturePayment

Logistics

Work Order&WIP Mgmt

7B



23/29

Virtual FactoryWO & WIP ChoreographyO

EM

/OEM

Su

7BxNotify of Forecast Reply

Supplier,Foundry,

Subcontractor,Contract

Manufacturer

7Bx

Manufa

cturer

plier

7B1

Request Work In Progress

Request Work In Progress Response

7B2


24/29

Virtual Factory Process ModelFactory Capacity Planning

Factory Capacity Planning -

Enables the exchange of thecontract manufacturersmanufacturing capability andcapacity information. It is

DemandCreation

Design Forecast

FactoryCapacityPlanning7B + 4A

use o commun ca e e

output equivalency units ofmeasure, equivalencyfactors, and availabilitytimes. A suite of 4A and 7B

PIPs have already beenengineered.

Order

ManufacturePayment

Logistics



25/29

Virtual Factory Process ModelProduct Data Management

Product Data Management -Enables the exchange BillOf Materials, ApprovedSuppliers List, EngineeringChange Request,En ineerin Chan e

DemandCreation

ProductDataMgmt

2C

Approval, EngineeringChange Orders,Engineering ChangeImplementationinformation between

supply chain partners. Thissuite of 2A and 2C PIPshave already beenengineered.

Order

ManufacturePayment

Logistics

Design Forecast



26/29

Virtual Factory Process ModelDesign Transfer

Design Transfer-

Enables the transferof engineeringdesign information to

DemandCreation

Design Forecast

.

Defines howmanufacturingdesign information isexchanged. No PIPsexist today in thisarea.

Or er

ManufacturePayment

Logistics

DesignTransfer

7A


27/29

Virtual Factory Process ModelProduct Genealogy & Quality

Product Genealogy &

Quality - Enables theexchange manufacturingproduct and processinformation to support

Order

Demand

Creation

Design Forecast

,

management andwarranty entitlement. NoPIPs exist today in thisarea however NEMI/IPChas defined standards for

this area that we canleverage.

ManufacturePayment

Logistics

Product

Genealogy& Quality7C


28/29

Virtual Factory Process ModelDirect Ship & 3PL

Direct Ship & 3PL -

Enables theexchange Logisticsinformation to the

DemandCreation

Design Forecast

direct ship to endcustomers directlyfrom the subcontractmanufacturer or

from a 3rd partylogistics provider.

Or er

ManufacturePayment

Logistics

Direct Ship& 3rd PartyFulfillment2B, 3C, 4C


29/29

Virtual Factory Process ModelConsigned Materials

Consigned Materials -

Enables the trackingof consignedmaterials through the

DemandCreation

Design Forecast

virtual manufacturingprocess.Order

ManufacturePayment

LogisticsConsignedMaterials

virtual factory amitom without swf

Documents