1. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Manufacturing Process Modeling in Systems Architectures Gregory Pollari Advanced Manufacturing Technology INCOSE International Workshop 2012 Jacksonville FL January 22, 2012

2. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Acknowlegements At Georgia Tech –Dr. Leon McGinnis, Eugene C. Gwaltney Chair in Manufacturing Systems and Professor –Dr. Ola Batarseh, Researcher –Dr. Volkan Ustan, Researcher At Rockwell Collins –Jim Lorenz, Manager Advanced Industrial Engineering –Dan Turner, Material & Process Engineer –Todd Boyle, Material & Process Engineer 2

3. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Model Based Manufacturing Challenge Desire early Manufacturing involvement during system design Requiring systems engineers to “speak manufacturing” is a challenge How can Manufacturing engage during the systems design phase without “getting in the way?” 3

4. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Today’s Manufacturing Analysis Workflow Two problem classes –Analytical (mathematical relationship, or rule, can be verified) –Visual (difficult to write a rule, but easy to see) Start at detailed design –ECAD (Electrical Computer Aided Design) –MCAD (Mechanical Computer Aided Design) –Rule checkers (geometric features) –Reports Auto-placed components Preferred parts Cost rollup Manufacturing Readiness Assessment (MRA) Virtual Prototype Models (visual) Manufacturing process modeling (discrete event simulation) Automate where possible 4

5. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Early DFx and Producibility Analysis 5 System Architecture Detailed Design Build Verify & Validate Deploy Requirements Models Architecture Models Implementation & Analysis Models Database (DOORS®) Factory & Supply Chain Models Architecture Languages (OMG SysML™, AADL, DODAF) MCAD, ECAD, DFx, Producibility, Visualization, Cost Discrete Event Simulator (ARENA ® ) Today’s Focus Start Here In the Future Evolve from focus on “in series” analysis of detailed design to include...... “in parallel” input during architecture trade studies...... Driving need to speak the language of Systems Engineering Reduce Cost Impact OMG SysML is a trademark of Object Management Group, Inc. in the United States and/or other countries.

6. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Enablers for Early Manufacturing Involvement 6 NDIA Manufacturing Division AMEC Committee –Spur funding to research pre-CAD physics-based producibility measures Georgia Tech “Domain Specific Language” project –OMG SysML is the “hub” for early involvement SAVI (System Architecture Virtual Integration) –Formal methods supplement visualization System Architecture Detailed Design Build Verify & Validate Deploy Requirements Architecture Models Architecture Languages (OMG SysML, AADL, DODAF) Start Here In the Future

7. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. OMG SysML “Hub” An Integrated Modeling Vision 7 Galorath SEER ® -H Parametric Cost Estimating tool ARENA ® Discrete Event Simulator Factory & Supply Chain Simulation Production Cost Estimates “Pin 1 Problem” & Design Rule Evaluation OMG SysML “Front End” User Interface AADL, etc. Supports Formal Methods Analysis SAVI Inter-Model Shared Property Consistency

8. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Manufacturing Process Model in OMG SysML Contains all the necessary inputs needed for an ARENA ® model –BOM, production schedule, resource, process routings/times Shows the graphical representation of the BOM (Bill of Material) and each part’s process routing 8

9. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. OMG SysML to ARENA ® Translation Process OMG SysML model (.uml) Formatted XML (.xml) Access® database (.mdb) ARENA® model (.doe) ARENA® metamodel (.ecore /.ecore_diagram) UML® metamodel (.url) ATL translation (.atl) XML definitions for ARENA®. ATL translation code based on the manufacturing DSL. UML®/OMG SysML definitions. XSL (.xsl) Unformatted XML (.xml) Java® (.java) 1 2 Using the Atlas Transformation Language (ATL) translation engine within the Eclipse™ framework, translate the OMG SysML model with the ATL translation script. During translation, the model’s UML constructs are compared with manufacturing DSL and the appropriate XML semantics for ARENA® are chosen. Create an OMG SysML manufacturing model in MagicDraw® and then export the OMG SysML file (XMI® export). XML format definitions. Java® script to format XML file. 3 Using the Java® engine within the Eclipse™ framework, format the translated XML to a format importable by Access with a Java® script. This formats the XML data based on Extensible Stylesheet Language (XSL) definitions. 4 Import the formatted XML file into a pre- built Access database. The database contains tables and relationships that are recognizable by ARENA®. XML data is placed in the appropriate tables. 5 Import the database into ARENA® discrete-event simulation software. This will create a model for simulation and analysis. Eclipse Model-to- Model Transformation™ project ATL Transformation Engine Java® Engine 9 Eclipse and Eclipse Model-to-Model Transformation are trademarks of Eclipse Foundation, Inc. Oracle and Java are registered trademarks of Oracle and/or its affiliates. Other names may be trademarks of their respective owners. XMI and UML are either registered trademarks or trademarks of Object Management Group, Inc. in the United States and/or other countries. Eclipse™ Environment Eclipse™ ATL MagicDraw ® Java ® Microsoft ® Access ® ARENA ® Simulation

10. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Translating OMG SysML to ARENA ® ARENA ® manufacturing model can be simulated to identify system capabilities/constraints –Production (overall/monthly) –Production lead times –Resource capacities –Bottlenecks Using these results, decisions can be made by manufacturing support teams ARENA ® model and statistics 10

11. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Who Uses Process Simulation? Boeing –Used ARENA ® to model entire manufacturing and logistics processes for 787 integration* Assembly lines across the U.S. Included suppliers of ~50 mechanical components Simulated Dreamlifter usage for global logistics Demonstrated potential effects of production ramp-up Many medium to large companies use process modeling** –Examples: Toyota, Ford, GM, Lockheed Martin, NASA, EADS, Bombardier, Lufthansa, Honeywell, Goodrich, Cessna, Pratt & Whitney, HP, IBM, UPS Colleges and universities –ARENA ® alone is used in over 150 programs in the U.S. and over 500 worldwide 11 * “Boeing: Integrated Production System Modeling Method” presentation at ArenaSphere 2010 conference, May 17-20, Las Vegas, NV ** Internet search November 2010

12. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Benefits of Process Modeling Projects Tactical applications: allows for elements in a system to be adjusted without interrupting the current state Strategic applications: allows for new systems to be created and examined before key decisions or investments are made Provides leadership with a decision support tool to aid in the decision making process –Generates data on which to base decisions –Helps to eliminate “best-guess” scenarios Identifies problem areas so effort can be focused where it will result in maximum benefit Helps communicate, promote change and receive buy-in from key stakeholders Gives stakeholders a better understanding of the entire system as a whole and the interactions that take place within the system –A model is essentially a living and breathing Value Stream Map! 12

13. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Integration Challenges Human Interface –Graphical user interface – “language” of systems engineers Formal methods/analysis – requires semantic precision Integration –OMG SysML is very flexible, graphical interface –AADL is semantically precise –MARTE, DARPA META translator: integrate OMG SysML-AADL XMI ® implementation for tool interoperability Automated connection with ERP (Enterprise Resource Planning) systems Need for producibility measures that can be applied during system design (research) Consistency checking of shared properties across model environments (SAVI – Systems Architecture Virtual Integration) 13 XMI is a registered trademark of Object Management Group, Inc. in the United States and/or other countries.

14. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. How Can MBSE Address these Challenges? Promote and drive toward certified XMI interoperability –Cax-IF (Computer Aided “x” Implementor Forum) model? Architecture language mapping to STEP AP-233 –OMG SysML to AP-233 mapping – is it complete? –AADL to AP-233 mapping Develop a layered systems architecture “data interchange” model for interoperability between architecture descriptions –Analogous to OSI (Open Systems Interconnection) model for communications architectures? –Abstract systems modeling language at the top (MOF ® ?) –Concrete data storage model at the bottom (AP-233?) –Architecture models can take various forms Language Instances Database File storage 14 MOF is a registered trademark of Object Management Group, Inc. in the United States and/or other countries.

15. © Copyright 2012 Rockwell Collins, Inc. All rights reserved. Contact Gregory Pollari Advanced Manufacturing Technology Rockwell Collins gmpollar@rockwellcollins.com 319-295-1629 15