1. Integrated Product, Process and Production Engineering Dr. Richard A. Wysk Leonhard Chair in Engineering The Pennsylvania State University University Park, PA 16827 rwysk@psu.edu http://www.engr.psu.edu/cim

2. Traditional Engineering

3. Quick Vision of Integrated Product, Process and Production Engineering

4. Product Engineering

5. Process Engineering

6. Production Engineering

7. A Vision of Integrated Engineering Systems (cont.) INTEGRATED PRODUCT, PROCESS AND PRODUCTION ENGINEERING (IPPPE) –tools and techniques that can be used to assist in combining planning, design, construction and management of a product.

8. A Vision of Manufacturing Systems (cont.) IPPPE –planning, designing, construction and management of a product.

9. Research Motivation Enterprise-based Engineering Integration Prevalent of manufacturing globalization, i.e., distributed manufacturing –Small batch production Leverage manufacturing capability Leverage capital investment Core competency focus –Geographically separated engineering experts Communication problem Time and availability Manufacturing cost saving during early design stage -- ‘concurrent engineering’ Business motivation

10. The Acid Test

11. Instance specific solutions Group Technology Parametric/feature-based modeling (most existing applications) CAPP DFx

12. How do we work on generic solutions? We’re all going In different directions!!!

13. Product Engineering Tools include: CAD, FEM, Dynamic simulations, … Good instance specific remedies

14. Process Engineering CAPP –Very instance specific knowledge Fixture and tool planning Path planning and NC code generation

15. Production Engineering Few tools Complex systems Interfaces

16. Models Used in IPPPE PDES/STEP for Product Engineering –Very Big Project –Scope Grows with Need PSL for Process Engineering –Not Real Process Plans –Very Large Scope Manufacturing Resource Model –Descriptive Entities –Not Very Detailed

17. Business Enterprise Model Product Model Production Model Form Function Material Tolerance Useful Life Method Equipment req’ts Fixturing Tooling Operating conditions Resources Resource capacities Resource status Resource cost Resource capabilities Process Model

18. IPPPE Directions Geographically Separated Engineering Activities Best Practice Only Time Compressed Horizons Open Access (Data and Manufacturing) Intelligent Access to Non-Expert Domains

19. Geographically Separated Engineering Web Connected Translators and Interpreters to/from Other Domains Software Assistants (or Agents) into Non-Expert Areas Use Best Method to Produce Design Use Best Manufacturing System/Practice to Produce Product Immediate Awareness of Capital Critical Constraints

20. Best Practice Only Domain Prejudice Dominates Process Engineering Hybrid Manufacturing –We Seldom Use A Single Manufacturing Technique DFx ∑ $ (DFx)

21. Time Compressed Horizons and Open Access “Better Late than Never” Has Become “Better Never Be Late” –Manage All of Your Resources Carefully Immediate Access to Supplier Critical Activities Well Informed Early Decision Making

22. Intelligent Access to Non-Expert Domains Critical Size and Tolerance Constraints Should be Available to the Product Engineer Non-Traditional Methods –Domain Prejudice (Powdered Process) Software (Intelligent) Agents Span Various Domains

23. Some Examples Resource Independent Process Plans Control from IPPPE

24. Methodology Requirement specification Vs. Description –Ex: Require hole making process that can achieve 0.5” diameter and 0.008 positioning accuracy –Ex: Twist drilling with 0.4687” diameter and boring a hole with 0.5” diameter Feature composition Vs. Feature decomposition Alternative processes -- AND/OR Directed graph Process planning decomposition Universal level process knowledge Process modeling abstraction Resource independent process representation [Brown and Ray 1987], [Wysk et. al, 1995], [Shah and Mantyla 1995], [Chang 1990], [Ray 1987]

25. Process Modeling Mech_rem _oper_info Chem_rem _oper_info Elec_rem _oper_info Therm_rem _ oper_info (ABS) Operation_level_information (ABS) Matl_transf_oper_info(ABS) Matl_transp_oper_info (ABS) Matl_ rem_oper_info (ABS) Geometry_ change_oper_info (ABS) Property_ change_oper_info (ABS) JoinAsm_ oper_info (ABS) Mfg_oper_info (ABS) Business_oper_info 1 1 1 1

26. Process Planning Decomposition in Association with the Alternatives 1. Precedence constraints due to geometric and topological constraints 2. Precedence constraints due to relocating the part adversely affects the repeatability requirement of a part 3. Precedence constraints due to geometric tolerance requiring extreme repeatability 4. Precedence constraints due to economical rationalization of machining 5. Process accuracy constraints 6. Technological constraints--available resources 7. Process economy Generate RSRS Generate RIOS

27. RIOS Schema RIOS_GraphRIOSRIOS_Process_level_informationRIOS_Operation_level_informationRIOS_SupportRIOS_Transaction Business and production requirements Alternative Resource type and workholding requirements Process type, accuracy,topology, and shape requirements Measurement, material, etc. specifications

28. Cost and Time Estimation of the Example Part ‘OLG: Get Feasible Machines’ Haas VF-OE (3-axis) and Haas VF-3B (5-axis): Prefer VF-OE due to cheaper burden rate

29. Automatic Generation of Simulation Models from Neutral Libraries: An Example Young-Jun Son, University of Arizona Albert T. Jones, NIST Richard A. Wysk, Penn State University

30. Example Job Shop System System Input Buffer System Output Buffer Penn1_in Penn3Penn2_inPenn2 Penn1Penn1_out

31. Database Information for the example system (1)

32. Database Information for the example system (2)

33. New concept of Simulation Modeling using Library Components Library of Simulation Objects For shop floor (Flow of Jobs) Model Builder Engine Simulation Data Analyzer Animation Visualization Model Description (Neutral) Specific Simulation Model Shop Floor (Real data) Statistical Results Animation Or Visualization Library of Simulation Objects For all applications User

34. Two Translators (Model Builders) Arena 3.01 ProModel 4.2 Model builders in Visual Basic 6.0 –Microsoft Access 8.0 Object Library –DAO (Data Access Object) 3.5 Library –Arena Object Library –ProModel 1.0 Type Library

35. Generated ProModel Model (1)

36. Generated ProModel Model (2)

37. Generated ProModel Model (3)

38. Generated ProModel Model (4)

39. Generated Arena Model

40. Summary Manufacturing systems are getting more complicated Manufacturing is becoming a Broad Area Activity Communication issues have increased Integration is key