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Database-centric

Production

Control Systems

Matt [email protected]

Product Manager

Autodesk

Global Product Data Interoperability Summit | 2017




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Biography

Matt Thorn is a Product Manager for Composites

Manufacturing at Autodesk. He received his BS in

mechanical engineering and mathematics from

Rutgers University and Stockton University

respectively after completing a 5-year dual degree

program. Matt began his expertise in advanced

manufacturing with Magestic Systems, a company

that was then acquired by Autodesk in July 2014.

With the Tru product portfolio, Matt continues to

innovate in the composite hand layup and automated

layup industries.





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Overview

• Enterprise Production

• Material Asset Tracking

• “Lights Out” Automation





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Enterprise Production





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Worldwide Organization

Phoenix

Water Jet

Andrew

Saw Cutter

Amy

Theresa

Philadelphia

Laser

Joe

Lisa

Plasma

Allessandra

Seattle

Fabric Cutter

Forrest

Sydney

Punch Press

Niranjana

Router

Samuel

Shanghai

Water Jet

Daniel

Mary

Punch/Laser

Ankit

Samir

Company

Shop Floor

Facilities

Machines

Enterprise Production Hierarchy





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Enterprise Production Workflow

LEGACY NCDATA

GENERIC CAD DATA

NATIVE CAD DATA

ERP/MRP SYSTEM

SHOP FLOOR

CNC LASER

CNC PUNCH

CNC WATER JET

CNC PLASMAREPORTS

PLM/PDM

INVENTORY

SALES ORDERS





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Database Architecture

F1

F2

F3

F4

F5

Enterprise

SAP

(ERP)C1

C2

CN

C1

C2

C1

C2

C1

C2

C1

C2

CN

CN

CN

CN

Facility DBs Client DBs

Master DB

• SAP feeds Job Order and

Inventory Info

• Master DB distributes

information to each facility

• Client DBs filter out Role

Specific data into unique

client environments





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Business Engineering Production

Enterprise Role Representations





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Business Setting up business rules

Foreign Keys

▪ Set up Facilities and Machine Groups

Machine Management

▪ Set up Machine List, Mach Groups, Facility, Mach Info, Mach

Settings

▪ 20 machines at Auburn facility

▪ MGroups need to match SAP nomenclature

▪ Need to procure Mach Info data from Boeing

Facility Staging Tables

▪ Material, Inventory, Production Order, Pick Request, Pick

Confirmation

▪ All read-only

Enterprise Role Responsibilities





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Engineering • Setting up feeds, speeds, nesting defaults, importing NNS

• Foreign Keys

• Set up Facilities and Machine Groups






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Production • Visualize everything sent to machine (SENT status)

• Receives Nest Plot (with barcode) and plates from inventory

• Tracking and documenting cutting operation from start to

finish

• Partial or Complete cut

• Reviewing nests

• Editing machine selection for nests as required

• Reposting for new machine

• Sending new NC to machine






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Nest Lifecycle

• SAP Order Inputs

• Order Numbers

• Priorities

• Due Dates

• Facilities

• Engineering Parts

• Assembly Information

• Inventory

• Material Grouping

• Machine Capacity

Planning

• Order Lifecycle

Management

• Tooling

Optimization

• Post Processing

• Cutting

Optimization

• SAP Inventory

Updates

• Re-allocation of

Inventory

• Cutting and Labeling

Operations

• Remnant Materials

enter Inventory

• SAP Order Updated

• Parts move to

Assembly Process





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Material Asset Tracking





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Carbon Fiber

Fiber Glass Foam

Concrete

Metal plates

Honeycomb

Coils

Bars – Extrusions - Rods

Honeycomb/sandwich panelsGrating

Materials





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Freezer Autoclave

CuttingLayup

Bar Code

RFID

Bar CodeBar Code

• Expiration dates for all plies

• In/Out time for all plies

• Remaining shelf life for plies

• Which Roll Each Ply Came From

RFID

Bar Code

Material Asset Tracking





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Workflow for Material Asset Tracking





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Freezer station

1. Automated freezer

2. Software driven

3. Feeds data to

TruNest

Material Storage





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Cutter station

1. Orders from ERP

2. RFID shows roll

3. Post for cutter

4. Bar code label

5. Bag label to printer

1 2

Material Processing





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Layup station

1. Come from cutter or

freezer

2. Bar code kit bag

3. Bar code tool

4. Trash / Transfer plies

1 2

3

Layup/Assembly





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Autoclave station

1. Bar code from tool

2. 4 autoclave

3. Prep station

4. IN status

5. Stops timer after 3

hours

1 2

3

Additional Processing





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TruNest with Cloud Production Management





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Work Instructions in the cloud





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Shop Floor Management in the cloud





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“Lights Out” Automation





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Automation Frameworks

• Nesting and Cutting Optimization

• Tooling Automation

• Software Automation Utilities





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Nesting and Cutting Optimizations

• Common Line Punching

• Automatic Part Tabbing

• Nest Around, Above, or In Clamp

Zones

• Automatic Clamp Repositioning

• Skeleton Cutting

• Detect & Destruct Floating Scrap

• Leverage Special Tooling

• Embossing & Labeling

• Reduce Number of Tool Changes

• Remnant Tracking





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Nesting and Cutting Optimizations




Zones












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On The Fly Programming




Zones












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Cutting machines: self contained factory

Punch machineLaser cutter

Suction cups Lift Master

Sheet removalMaterial towers





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Software Automation Utilities





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Questions?

Email: [email protected]





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Autodesk and the Autodesk logo are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product

names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product and services offerings, and specifications and pricing at any time without notice, and is not

responsible for typographical or graphical errors that may appear in this document.

© 2017 Autodesk. All rights reserved.

database-centric production control systems...gpdis_2017.ppt | 6 worldwide organization phoenix...

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