SMART ASSEMBLY

1
SMART ASSEMBLY

• Next generation capability in assembly systems
  and technology which integrates assembly
  processes, people, equipment, and information
  using both virtual and real time methods to
  achieve dramatic improvements in productivity,
  lead time, and agility.
• Jim Caie
• ARC Advisory Group

2
Manufacturers Face Formidable Challenges
What Is Driving Mfg Operations Today?
Dynamic Customer Requirements
Niche Products
Worker Safety
3
SMART ASSEMBLY MEETS THE CHALLENGE
COMMON, SAFE, AND SMART ENVIRONMENT FOR MAN
MACHINE
KNOWLEDGEABLE, EMPOWERED WORK TEAMS
INTELLIGENT MODELLING, OPTIMIZATION, AND
VALIDATION OF ASSEMBLY PROCESSES
FLAWLESS EXECUTION OF SUPPLY CHAIN AND PRODUCT
LIFE CYCLE PROCESSES
EFFECTIVE INTEGRATION OF AUTOMATION AND
INFORMATION TECHNOLOGY INTO THE HUMAN ASSEMBLY
PROCESS
4
SMART ASSEMBLY REQUIRES BOTTOM UP COLLABORATIVE
MANUFACTURING
Business Processes
Enterprise Systems
Standards-Based Integration Methods
Network/Internet Standards
OAGIS/S-95
Process Schemas
Manufacturing Processes
Factory Operations
Control Device Networks
5
Success in Smart Assembly Depends on Successful
Product Lifecycle Management
Product Lifecycle
Product Domain
Production Domain
Controls/Tool Engr
RD
Design Engr
Factory Operations
Org
Mfg Engr
Industrial Engr
Design, Produce Tools, Jigs, Fixtures,
Automated Systems
Obtain, Operate, Control, Maintain Equipment
Automated Systems to Manufacture Products
Work Flow, Mfg Processes
Materials Product Research
Process Planning
Product Design
Processes
Scheduling Resource Mgmt Mfg Intelligence Q/A Visi
bility Supply Chain Synchronization
. STRATEGIC ENGINEERING . VALIDATED
PROCESS . VALIDATED EQUIP
. DESIGN FOR ASSEMBLY,
DESIGN TOOL
DESIGNS RECYCLING, ENERGY USE .
ERGONOMICS . VALIDATED
CONTROLS

. VALIDATED SAFETY
Function (Systems)

CAD/CAM DIGITAL MANUFACTURING
Engineering
Operations
6
NEXT GENERATION ASSEMBLY BUSINESS MODEL

• New Drivers
• More Speed Agility
• Lower Investment
• Continuous launches

VOLUME
NicheProd C
Flex plant handles Peak volumes and Niche products
Niche Prod B
Niche Prod A
FLEX PLANT
Peak Prod 3
Peak Prod 2
Peak Prod 1
____
Standard plants run at 100 capacity handing
70-80 of peak demand
STD. PLANTS
TIME
7
SMART ASSEMBLY CONCEPTUAL MODEL

• Finished Product
• On Schedule
• Zero Defects
• Lower Production Costs
• Meets Market Customer
• Demands

8
SMART ASSEMBLY - VISION

• PEOPLE
• Knowledgeable, Empowered Teams
• INFORMATION Event-driven, Real- time
  and Actionable
• PROCESS Strategic, Lean, Agile,
  Flawless Execution
• TECHNOLOGY Shared, Safe, Effective,
  Efficient Work Environment for Humans Machines

9
SMART ASSEMBLY VISION - PEOPLE

• Corporate Culture Enabling Knowledgeable,
  Empowered Work Teams
• Performance Oriented Training Practiced
• Virtual Training Exploited
• Effective Transfer of Process Knowledge
• Initiatives to Empower Knowledge Workers
• Empowered Teams Managing their Work
• Plan
• Execute
• Verify
• Continuously Improve

10
SMART ASSEMBLY VISION - INFORMATIONReal time and
actionable

• Real time, actionable information enables
  knowledgeable, empowered teams to achieve
• Continuous learning and improvement
• Zero defects, waste, and accidents
• Cost effective, on time performance
• Mutual support
• Key elements of real time, actionable information
  
• Open, modular, scalable, distributed,
  configurable
• Vertical Integration of Plant Floor to Enterprise
• Event Driven Manufacturing
• 100 electronic collaboration capability
• Visibility to all operations and operators
• Adaptive control
• Predictive management systems
• Automatic parts/subassembly tagging and tracking
• Wireless control, MES, and hand held HMIs

PLC SOFTWARE
I/O
HMI
11
SMART ASSEMBLY VISION - PROCESSESStrategic,
Lean, Agile, Flawless Execution

• Seamless order to make capability
• Build anywhere capability
• Lean, Agile assembly conveyance systems
• Correctly Build in Work Station Capability
• Fixtureless assembly processes
• Sequenced material delivered to point of use
• Flawless supply chain management execution
• Flawless product life cycle management execution
• Six sigma institutionalized

TWO KEY ENABLERS
Strategic Engineering Systematic approaches for
designing families of products that can
accommodate changes in market trends and evolving
technology innovation
Digital Manufacturing Virtual tools that
optimize and validate manufacturing process,
equipment, and controls designs
12
SMART ASSEMBLY VISION - TECHNOLOGYOptimized
assembly system

• Intelligent, safe robots
• Intelligent, flexible conveyance systems
• Automatic error proofing
• Virtual simulation and validation of processes
  and controls
• Process knowledge capture/implementation
• Visualization and mfg intelligence dashboards
• Automatic safety and optimization of the assembly
  system
• Automatic, intelligent adoption to assembly
  problems
• Electric actuators
• Nano devices

Technology Enables shared, safe, effective work
environment for people and machines
13
SMART ASSEMBLY - USER STRATEGY
Smart Assembly Best Practices
People Process Tech Info
Ground Breaker
Leader
Competitor
Follower

• USERS
• Must understand the value and cost of moving to
  the next level of smart assembly best practice
• Must have a validated plan before executing

14
SMART ASSEMBLY PROGRAM COLLABORATION MODEL
R D GROUPS USER GROUPS SUPPLIER GROUPS

• PLAN
• DEVELOP
• BUILD
• VALIDATE
• DEPLOY

• All stakeholders involved in all program phases
• Deliverables implemented in small pieces as soon
  as they are available
• Standards strictly enforced to ensure competitive
  sourcing and easier deployment

15
SMART ASSEMBLYPOTENTIAL PROGRAM STAKEHOLDERS
RD PROVIDERS USERS SUPPLIERS

Auto RD Centers Ford, GM, DCX Siemens, Rockwell
Universities USCAR Schneider Elec
Govt Labs Boeing Fanuc,ABB,Kuka
NASA Gen Dynamics UGS, Desault
Stakeholders Fund program with money and/or
resources

• ARC, RIA, SP-95,OAGIS,STEP

16
SMART ASSEMBLY PROGRAM
MANAGEMENT MODEL

• Steering Committee
• consists of Chair voting members
• /labor contributions determine voting rights
• Members from user, RD, and suppliers
  organizations
• Approves vision, RD work, and detailed
  application plans

Steering Committee
R D Working Group
Planning Group
Project Execution Teams

• Proj teams execute specific projects
• Teams disband after project completion

Proj A

• Establishes and refines vision
• Defines objectives, timetables, resources
  metrics
• Measures actual performance

• Identifies, finds, and/or develops technology
  that is leveraged across all projects

Proj B
Proj C
Proj C
Proj C
17
SMART ASSEMBLY PROJECT
EXECUTION MODEL
RESEARCH AND DEVELOPMENT
US CAR
BUILD VALIDATE
DEPLOY
PHASE 1 PLAN
GM
VISION
NIST
PHASE 2 PLAN
BUILD VALIDATE
DEPLOY
BOEING
ALL STAKEHOLDERS
PHASE 3 PLAN
Planning Group
BUILD VALIDATE
DEPLOY
RD Group
Project Execution Teams
18
SMART ASSEMBLY PROJECT PLANNING
Applications

• Each company brainstorms to identify which
  assembly processes are the best to automate
• - Low hanging fruit
• - Cost/benefit of automating the
  application
• - Learning impact
• Company representatives meet to
• 1. Categorize and prioritize which assembly
• processes to automate
• 2. Identify deployment projects and commit
• to support them with /resources
• 3. Get plant commitments to deploy at their
• sites

19
SMART ASSEMBLY PROJECT PLANNING
Research and Development

• All stakeholders interested in RD form a RD
  committee
• RD committee identifies the practices,
  processes, and technology required for Smart
  Assembly
• - What already exists
• - What needs RD
• RD committee determines how to best execute the
  RD and seeks required funds and resources
• - Government labs and agencies
• - Universities
• - User company RD centers
• - Supplier RD centers