Di 24 10 Estrel Hall C5+6 11.30 h - 12.30 h Ralf Stetter ... · • Create/Use Tools in MRL • Select required tools for Manufacturing Step in MRL and add to Shopping Card • Save

Presentation date: 24.10.2017Presenter Name: Ralf StetterCompany Name: A+B Solutions GmbHContact Information: [email protected] name: Estrel Hall C5+6Presentation Title: Using Teamcenter for Part Manufacturing in a competitive environment

Ralf StetterManaging DirectorA+B Solutions GmbH

Using Teamcenter for Part Manufacturing in a competitive environment

Restricted © Siemens AG

Page 3 Siemens PLM Software

Challenges





Ideal World

CAMPart model preparation Tooling and fixture design CNC / RobotsDNC Shop floor program

validation

CMM programming CMM inspection executionResource ManagementShop floor data accessResource LibrariesProcess planning

ProductionPlanning

Part Manufacturing Data- / Resource- & Process-Management



Information Flow Across the Entire Enterprise

ProductionProduct engineering

Manufacturing engineering

Operation Silos with Disconnected Systems



MachineTool

Tool Management

Quality MeasurementDNC

CNC Controller

Order ManagementFixture Design

CAM - NC programming

Work Instructions

Process Planning

ResourceManagement

CAD

Stage Model

Part Manufacturing Solutions- The challenge: Disconnected systems

Do we use right part revision?

Different databases!

Separate niche applications!

Which machine tool is this for ?Where is the tool ?

Is this the right and released Work instruction?

Wrong NC File!

IDC report estimates that information workers spend 13 hours a week with information gathering and analysis. An enterprise employing 1,000 knowledge workers wastes at least $2.5 to $3.5 million per year searching for nonexistent information, failing to find existing information, validating the information or recreating information that can‘ t be found.



• Quality escapes at the shop floor

• Product introduction is delayed & delivery target dates missed

Lack of Integration: The consequences

• Late changes consume time and cost:up to 30-50 hours per change

At the point of production:



Product Assembly

Produkt

CAD FileDrawing

VisualizationDocumentation

Revision/Effectivity

Produkt

CAD FileDrawing



Produkt

CAD FileDrawing



NC

processN

C process

NC

process

NC

progra

m

NC

progra

m

NC

progra

m

ToolingTooling

Tooling

FixturesFixtures

Fixtures

Gages

Gages

Gages

FacilitiesFacilities

Facilities

Machines

Machines

Machines

Capacity

Capacity

Capacity

InspectionInspection

Inspection

Production Engineering

Assy sequenceAssy sequence

Assy sequence

Detail activities

Detail activities

Detail activities

Resources

Resources

Resources

FacilitiesFacilities

Facilities

VisualizationVisualization

Visualization

Machine sim

Machine sim

Machine sim

Ergonomics

Ergonomics

Ergonomics

Line balanceLine balance

Line balance

Process simProcess sim

Process sim

Reports

Reports

Reports

Docum

entsD

ocuments

Docum

ents

MES

MES

MES

Knowledge

Knowledge

Knowledge

Improvem

entIm

provement

Improvem

entAssembly Planning

InstructionsInstructions

Instructions

PlanningPlanning

Planning

VisualizationVisualization

Visualization

ValidationValidation

Validation

Root C

auseR

oot Cause

Root C

ause

Quality

Challenges of Data Volume

The data volume for the production can be a hundred times the development …

Product Assembly

Product

CAD FileDrawing



Product

CAD File

DrawingVisualization

DocumentationRevision/Effectivity

Product

CAD FileDrawing



100 components can easily generate 10.000 production data



Current Situation



PDM/PLM

Engineering

Manufacturing Engineering

ResourceManagement

I-deas Solid Edge

CATIA Pro/E AutoCAD

SolidWorks

NX

Mentor (PCB)

MultiCADI-deasI-deas Solid EdgeSolid Edge

CATIACATIA Pro/EPro/E AutoCADAutoCAD

SolidWorksSolidWorks

NX

Mentor (PCB)Mentor (PCB)

MultiCAD

Real Life

ERPMS Office

SeparateDatabase

NC-Programming

FolderFiles

Shop Floor

Machine FoldersFiles



Conclusion

• Redundant Data

• Unsafe Processes

• Defective

• Big risk of waste production

• Liability / Compliance

• High organizational effort

• Time consuming

• Knowledge in individuals



Projects



KMWE



KMWE

• Reduce lead time

• Improve data management• Regulatory compliance

• Supplier to aerospace, machinery and medical industries

• 86 Million € revenue, 550 employees

Company overview Objectives



Facts

• Overall 12.000 parts to manage

• Low volume high complexity

• Focused on manufacturing

• 8000 different products a year

• 15% of new parts every year

• 20% of changes

• Average 3 NC programs per part

• Over 64 Tooling machines

• Several worldwide production locations

• Need to manage traceability (personalized processes)



Sharepoint

ProjectEngineering

Manufacturing Engineering

ResourceManagement

I-deas Solid Edge

CATIA Pro/E AutoCAD

SolidWorks

NX

Mentor (PCB)

MultiCADI-deasI-deas Solid EdgeSolid Edge

CATIACATIA Pro/EPro/E AutoCADAutoCAD

SolidWorksSolidWorks

NX

Mentor (PCB)Mentor (PCB)

MultiCAD

Prior Situation

SharepointMS Office

TDMSystems

NC-Programming

FolderFiles

Shop Floor

Machine FoldersFiles



Prior Situation

• File and folder based data management

• Manual activities like copy and paste for releasing/unlreleasing and archiving data

• Manual workflows

• Status by emails

• Highly paper based shop floor documentation

• Redundant data

• Lot of different systems who create their own data



Challenges

• High risk of using the wrong data

• Time consuming processes

• Workflows based on experiences and people

• No real change management for manufacturing

• Processes not enforced

• No traceability (who, when, where, why, what,……)

• Rely on a mixture of media (email, paper, files, folder names…….)

• Unmanaged change requests from shop floor

• Different data locations



Challenges

• Hard to find the right data (based on user experiences)

• Low flexibility

• No control for concurrent engineering and manufacturing

• No management of multiple sites

• Folder DNC



Solution

• One single source of data and process management

• Automated processes (workflows)

• Revision and access control

• Manage data dependencies

• Manage customer projects

• Integrate data from customer

• Manage CAM processes and data from EdgeCAM and NX CAM

• Manage Vericut data

• Manage CMM data

• Manage manufacturing work packages (NC programs, SFD, tooling data, TBD,….)



Solution Map

Tool managementTool librariesProcess

planning

ProductionPlanning

Tooling and fixture design CAMPart model

preparation

CAQ CMM inspection execution

DNC

Shop floor data access

Shop floor program validation CNC

Teamcenter Project, Cost, Data & process management

Tool/Product Cost Calculation

ProjectManagement



Aerospace Customer



Actual Process and Solution Landscape

Catia tool DBExcel

Catia tool DBCatalog

Catia Vericut script

Campost tool DBExcel

Campost tool DBCsv

Campost

DNC NC Machine

Vericut tools(TLS file)

Vericut tool DB(TLS files in XML format)

CATV

APT file NC file

DesignFixtureStock

(CATPart files)

VCProjecttemplateVericut tool fileVericut machine

VCProjectVericut tool fileVericut machineNC fileDesign modelFixture modelStock model

CCVBatch execution

VERICUT

DesignFixtureStock

(STL files)

Simulation OK?

DNCADM

Yes

NC file NC file

CATProcess

Catia batch

NC Programming process

Björn Olsson 2016-02-19

MRL?1. User creates the NC program in Catia and

save the CATProcess file.2. User runs CCV which

1. Run Catia and create APT file2. Run Campost and create NC file3. Run Vericur script and create

Vericut tool file and CVProjecttemplate file

4. Start CATV3. User run CATV which creates model files and

start Vericut



ShopfloorMachines

Teamcenter Part Manufacturing Optional - Single Source Manufacturing Landscape ready to connect

CATProcessCatia Batch FileAPT File

Tool master dataTechnology dataTool classification

NC-Workpackages

NC-ProgramsWork instructionsSetup instructionsTooling Sheets / Tool Presetter DataShop DocsVericut Simulationetc.

Manufacturing Resource Library

CATIA CAM

DNC

...

Shop Floor Integration (SFC)

Teamcenter Data and process managementTeamcenter Manufacturing Data-/Resource- & Process-Management

Tools NC-Program

ICAMCAM-Post

ToolsAPT File

ToolsAPT FileNC-Program

VERICUTVericut Project FileSimulation File

OptimizedNC-Programs

CATIA TC Interface



Step 1 CATIA CAM Integration

• Create Manufacturing Operation in TC

• Create/Use Tools in MRL

• Select required tools for Manufacturing

Step in MRL and add to Shopping Card

• Save of Shopping Card

• Automatic creation of shopping card tools

over mapping solution as CATIA Tool

Catalog

• CAM programming with tool catalog and

other resources

• Management of CATIA output files and

reference of used tools in TC Manufacturing Operation Step

MRL TC CatProcessCATIA

1) Add 3D Model Tool from TC/MRL

2) Add Tool from Catalog



MRL 2 Catia

Classified Tool Assembly and - Component Items

• Tool Component contains NX and Catia Dataset• Tool Assembly contains NX and Catia Dataset, • BOM View Master is Catia

Catia Models contains all relevant CAM attributes eg• Cut / No Cut geometry definition• Coordinate Systems• …



Search Tools in MRL ad to card



Step 2 CAM-Post

• Based on the referenced used tools in the

TC Manufacturing Operation automatic creation

of tool list for CAM-Post over mapping solution

• Start of CAM-Post with tool list and APT file input

• Management of CAM-Post output (NC-Program)

in TC Manufacturing Operation Step

ICAMCAM-Post



Step 3 VERICUT

• Creation an management of Vericut Projects in TC

• Usage of referenced tools from TC Manufacturing

Operation Step

• Output of Vericut Project file with mapped tooling

list and start of Vericut simulation and verification

• Input Management of Vericut simulation file in TC

Manufacturing Opartion Step for later usage

in Shop Floor

First Vericut Teamcenter Interface still released (V8.1) from CGTech

(visit their booth in the partners hall)

VERICUT



Solution for Competitive Integration



Teamcenter as Integration Platform for 3rd party Manufacturing Solutions

• CAM Integrator – Integration of 3’rd party CAM solutions in Teamcenter such as § UNC, OPUS, Exapt, MasterCAM, SurfCAM, EdgeCAM, WorkNC,

Powermill, Hypermill, Vericut…..

• Connection platform for shop floor solutions like:§ Flexible Manufacturing Systems (Soflex, Fastems)§ PCDMIS (Hexagon Metrology, Zeiss,…..)§ Job Shop Management (Siemens)§ Simatic IT MES for Part Production (Siemens)§ Presetter Solutions (Zoller,….)

Ask us if you have requirements to integrate other manufacturing solutions to get data from Teamcenter!



Integrating 3rd party CAM Software

Teamcenter

Shop Floor Connect DNC

3rd Party CAM Data Management in Teamcenter

3rd Party CAM access to TeamcenterMRL

Shop Floor Integrate Resource Mgt

3rd party CAM

Manufacturing Resource Library (MRL)

3rd party CAM

Scalable 3rd party Integration

3rd Party Data Management • Integrates 3rd party Software to Teamcenter• Manages foreign Source File in Teamcenter• Managing 3rd party Data inside Teamcenter using

same data model as NX CAM integration• Store CAM Output (NC Programs, Tool list, Shop

Doc into MENC Item)3rd Party access to MRL• Push Tools from Teamcenter MRL to 3rd party

software • Build / upload tool list (as BOM) to TC

(MENCMachining Item) for Shop Floor usage SFI RM

Both licenses can be used individual or in combination

CAM Data MgtTool Mgt

NC Data Mgt MRL to 3rd party CAM Tool Data Mapping



3rd Party CAM Data Management in Teamcenter

You can

• Integrate data from a 3rd party CAM / Manufacturing System thru a configurable interface into standard Teamcenter data model (MENCMachining Operation/ Item – standard Manufacturing Work Package). Creates Operations, Revisions, Activities and Attachments

• Integrate data from a 3rd party Simulation System

• Use the Teamcenter Manufacturing Resource Library

• Support of the Teamcenter functions like „New“ or “Revise” for new creation of a MENC Machining item structure or „Add“ to attach new datasets to existing MENC Machining Item

• Legacy data import (mass data import)

• Reads the existing data information from the header of NC program, file name, folder structure and even other sources like Excel to create the MENCMachining item structure

• Shop Floor Connect DNC Integration (add-on Module)Data from external system in Teamcenter can also be viewed and the NC / CMM programs can be down- and uploaded to the NC / CMM machines via Shop Floor Connect



Teamcenter Manufacturing integrations we are working on

• Autodesk Powermill (Delcam)

• Tebis

• NCSIMUL Machine

• Vericut

• Hexagon

• Zeiss

• Soflex



Teamcenter for Part ManufacturingThe Ideal World

CAMPart model preparation Tooling and fixture design CNC / RobotsDNC Shop floor program

validation

CMM programming CMM inspection executionResource ManagementShop floor data accessResource LibrariesProcess planning

ProductionPlanning

Teamcenter Data- / Resource- & Process-Management Solution



Thank You!Questions?A+B Solutions GmbH

Lorcher Str. 141/573529 Schwaebisch Gmuend

GermanyTel.: + 49 71 71 / 92 740 – 0

Fax: + 49 71 71 / 92 740 – [email protected]

www.plm-europe.orgwww.siemens.com/plm

October 2017

Documents

Di 24 10 Estrel Hall C5+6 11.30 h - 12.30 h Ralf Stetter ... · • Create/Use Tools in MRL • Select required tools for Manufacturing Step in MRL and add to Shopping Card • Save