digital twin digital thread in aerospace - siemens plm ... support a model based enterprise, digital...

Digital Twin – Digital Thread in Aerospace David Riemer

Realize innovation.Unrestricted © Siemens AG 20XX

Unrestricted © Siemens AG 2016

Siemens PLM SoftwarePage 2

Siemens Focus is to Enable Excellent Performance on Every Program

Fully support a Model Based Enterprise, Digital

Twin – Digital Thread to better meet cost,

technical and schedule program goals

Program Execution Excellence

Leverage the smart innovation Portfolio to enable

product knowledge & definition to be shared to

improve performance in production, support and

future bids

Provide pre-configured technology to focus on

the automation of specific A&D value streams to

provide a potential competitive advantage



Industry 4.0 – What Is It?

The history of the industrial revolution

1. Industrial revolution

Introduction of mechanical production plants using water and steam power


Introduction of mass production based on the division of labor using electrical

energy


Introduction of electronics and IT to increase the level of automation


Intelligent automationand integration of physical & virtual worldEnd of 18th century

End of 19th century

1970

2015-2020

Mechanical loom

Siemens single-phase

generator

Industry 4.0

Programmable

Logic Controller

An industrial revolution was always drivenby new enabling technologies



Industry 4.0

Defining the way forward in industry in the internet age



Why Hasn’t the Digital Age Yielded the Benefits Expected?

What’s the difference?

No difference



Why Hasn’t the Digital Age Yielded the Benefits Expected?

Digital Twin Maturity

Dig

ital T

hre

ad M

atu

rity

Problem

• Today the digital

information we store is not

connected to any of the

inputs or requirements –

making it difficult to fully

understand a proposed

change.

• A&D has unique product

life spans that require full

traceability

Digitalization – Not only is the

physical world virtually

verified prior to design,

process, tooling, etc.

commitment – all the inputs,

outputs and process used to

create the information are

completely traceable.

Digitize

Digitize

Digitalization

Digitize

Where is Your Organization?



Digital Thread – Creating the Digital Twin

PhysicalEngineering Manufacturing

MCAD

ECAD

Software

Structure

MBOM

BOP

As-tested

As-built

As-maintained

Requirements

Customer

Regulatory

Design

Build

Program Plan and

Execution

SOW

Work Pkg.

Schedule

Cost

Systems

Engineering

Functions

Logical

Architecture

Verification




Value Stream Solutions Generate Competitive Advantage

FASTER TIME

TO

CERTIFICATION

Verification

Management

INTEGRATE

SERVICE WITH

THE FACTORY

Product Support

Planning and

Management

MEETING COST

& PRODUCTION

GOALS

Product

Realization


Value Streams on the Smart Innovation Portfolio

EFFECTIVE

SUPPLIER

MANAGEMENT

Supplier Source

Selection and

Management

MEETING COST,

SCHEDULE AND

TECHNICAL

REQUIREMENTS

Integrated

Prog. Planning

and Execution

EFFICIENT

FIRST TIME

RIGHT

Product

Design

OPTIMIZATION

& INNOVATION

Systems

Driven Product

Development

Enabling

traceability from

requirements thru

virtual and physical

test to ensure

product

verification.

Design for support.

Plan for support.

Manage service

planning. Closed

loop support with

manufacturing and

design.

“Shift left”

manufacturing

planning to ensure

cost, schedule &

safety goals are

achieved with fully

integrated factory.

Enabling

traceability from

OEM requirements

to suppliers.

Proactive supplier

management.

A systems

approach to

project planning a

fully planned,

resourced

,budgeted and

executed program

management

solution.

Design with

advanced

materials,

integrated

CAD/CAE,

maximize reuse,

advanced

configuration

management.

A systems driven

product

development

approach to

leverages system

and 3D models

from idea thru

support.




Using world class capabilities to generate business value

Product Support Planning and Management

Product Design

Supplier Source Selection and Management

Product Realization

Industry

Value

Streams

Smart Ideation Smart Realization Smart Utilization

Reporting and

Analytics

Requirements

Management

Model Based Systems

Engineering

AutomationDesign &

Commissioning

Mechanical Design

Model Based

Definition

End-item

Delivery (DD250 or

Airworthiness)

As-designed BOM

Management

MBOM and Bill of

Process

Reliability and System

Safety

CAM / Tooling /

Fixtures

Assembly

Manufacturing

Engineering

Advanced

Aerostructure

Design

3D Electronic Work

Instructions

Material and

Compliance

Management

Technical

Publications

(S1000D)

Maintenance

Planning

Failure Reporting &

Corrective Action

Logistics Support

Analysis

Advanced

Manufacturing

As-Maintained

BOM

1D / 3D Simulation

and

Test Management

Plant

Design &

Optimization

Document

Management

(CDRL/SDRL)

Quality

Management

Manufacturing

Execution

Management

Supply

Chain

Collaboration

Software

Management

Electrical and

Electronics Design

Configuration and

Change MgtIP Protection and

Export ControlSchedule, Cost & Risk

Management

Part

Manufacturing

GSE/EGSE Design

Spares Definition and

Condition of Supply

Maintenance

SimulationService Bulletins

3D Massive Model

Visualization

Capabilities

Manufacturing

Operations

Management

ERP

Integration

Software

Maintenance

Maintenance

Ergonomic

Analysis

Field Experience

Feedback

Obsolete

Management

Manufacturing

Optimization MRO

Integration

Verification Management

Digital Enterprise FoundationSmart

Innovation

Portfolio

Systems Driven Product Development

Integrated Program Planning and Execution






Product Design


Product Realization

Industry

Value

Streams


Reporting and

Analytics

Requirements

Management

Model Based Systems

Engineering

AutomationDesign &

Commissioning

Mechanical Design

Model Based

Definition

End-item

Delivery (DD250 or

Airworthiness)

As-designed BOM

Management

MBOM and Bill of

Process


Safety

CAM / Tooling /

Fixtures

Assembly

Manufacturing

Engineering

Advanced

Aerostructure

Design

3D Electronic Work

Instructions

Material and

Compliance

Management

Technical

Publications

(S1000D)

Maintenance

Planning

Failure Reporting &

Corrective Action

Logistics Support

Analysis

Advanced

Manufacturing

As-Maintained

BOM

1D / 3D Simulation

and

Test Management

Plant

Design &

Optimization

Document

Management

(CDRL/SDRL)

Quality

Management

Manufacturing

Execution

Management

Supply

Chain

Collaboration

Software

Management

Electrical and

Electronics Design

Configuration and



Management

Part

Manufacturing

GSE/EGSE Design


Condition of Supply

Maintenance


3D Massive Model

Visualization

Capabilities

Manufacturing

Operations

Management

ERP

Integration

Software

Maintenance

Maintenance

Ergonomic

Analysis

Field Experience

Feedback

Obsolete

Management

Manufacturing

Optimization MRO

Integration



Innovation

Portfolio





Connected and Integrated Data – Digital Thread – Digital Twin

Requirements

Customer

Regulatory

Design

Build

Systems

Engineering

Function

Logical

Architecture

Verification

Simulation

Behaviour

Reliability

CAE

Manufacture

Support

Engineering

MCAD

ECAD

Software

PhysicalManufacturing

Assembly

MBOM

Process

As-tested

As-built

As-maintained

Benefit:

Ability to completely trace a

requirement through the

design to the shop floor

Provide the knowledge base

to manage the product

throughout its extended

life(~>40 years)

Complete and thorough

change management –

Absolutely know ALL the

impacts of a proposed

change



The Reliability Digital Thread

System

Reliability

Mission

Reliability

Economic

Service

Life

Environmental

Manufacturing

Process

Control (CPk )

Design

Usage

Analysis

Architecture

Fault IsolationMean Time to

RepairNo-Fault Found



MADe – how it supports the “V”

End-item

Requirements

System

Requirements

Component

Requirements

Design System

Verification

Component

Verification

End-item

Verification

Failure

Hazard

Analysis

Fault Tree

Analysis

Common

Cause

Analysis*

Failure

Hazard

Analysis

Preliminary

Fault Tree

Analysis

Common

Cause

Analysis*

Preliminary

Fault Tree

Analysis

Common

Cause

Analysis*

Physical

Hardware

Software

Failure

Mode &

Effects

Analysis

Failure

Mode &

Effects

Summary

Update

Fault Tree

Analysis

Common

Cause

Analysis*

Failure

Mode &

Effects

Analysis

Failure

Mode &

Effects

Summary

Update

Fault Tree

Analysis

Common

Cause

Analysis*

Update

Fault Tree

Analysis

Common

Cause

Analysis*

Logical Architecture

Also includes:

• Teamcenter Integration

• RAM tools

• Prognostics & Health

Management tools



WHY ALM + PLM

Each domain has unique needs

Design dependencies cross domains

Each solution provides unique benefits

Customers require engineering synergy

Domain expertise needs to be seamlessly

integrated

PLM & ALM must work in unison to address product development demands

Software Engineering

ALM

Hardware

Engineering

PLM

EE

Engineering

PLM

Embedded

Engineering

ALM+PLM




Integrated ALM + PLM

Multi-Domain Lifecycle

Management

Systems Architecture

and Modeling

Domain Traceability

and Configuration Management

Product Line Traceability of

physical requirements to the

BOM

Ensure requirementsare met from design

through manufacturing& service

Intelligently assess the impact of

requirements or design changes

Physical Lifecycle

Traceability of softwarerequirements to test

cases, work packagesand code

Ensure requirements are met from design

through coding, testing build & release

Intelligently assess the impact of

requirements or design changes

Software Lifecycle

Requirements Decomposition

Systems Level Impact

Analysis

Domain Realization

Teamcenter

Teamcenter

ALM Connector for Teamcenter

ALM (Ex: Polarion)






Product Design


Product Realization

Industry

Value

Streams


Reporting and

Analytics

Requirements

Management

Model Based Systems

Engineering

AutomationDesign &

Commissioning

Mechanical Design

Model Based

Definition

End-item

Delivery (DD250 or

Airworthiness)

As-designed BOM

Management

MBOM and Bill of

Process


Safety

CAM / Tooling /

Fixtures

Assembly

Manufacturing

Engineering

Advanced

Aerostructure

Design

3D Electronic Work

Instructions

Material and

Compliance

Management

Technical

Publications

(S1000D)

Maintenance

Planning

Failure Reporting &

Corrective Action

Logistics Support

Analysis

Advanced

Manufacturing

As-Maintained

BOM

1D / 3D Simulation

and

Test Management

Plant

Design &

Optimization

Document

Management

(CDRL/SDRL)

Quality

Management

Manufacturing

Execution

Management

Supply

Chain

Collaboration

Software

Management

Electrical and

Electronics Design

Configuration and



Management

Part

Manufacturing

GSE/EGSE Design


Condition of Supply

Maintenance


3D Massive Model

Visualization

Capabilities

Manufacturing

Operations

Management

ERP

Integration

Software

Maintenance

Maintenance

Ergonomic

Analysis

Field Experience

Feedback

Obsolete

Management

Manufacturing

Optimization MRO

Integration



Innovation

Portfolio






Only Integrated Solution – Program Digital Thread

IPP&E Process diagram

• Process uses a “Common WBS” to organize all

bid/program information

• Bases on set of criteria applied to the “Common

WBS” a Program WBS is created

• Work Package includes requirements,

processes, inputs, deliverables, logical,

functional and physical architectures

• Complete support for Integrated Master Plan,

Integrated Master Schedule and third party

EVMS systems

• Complete configuration management of all

program artifacts

Phase 1 Catalyst – Late fall 2016

../../Integrate Program Planning and Execution/IPPnE_Process._Rev I.vsd



Organize Common and Program Around WBS

Totally Integrated and Traceable

WBS

Element

IMP

Criteria

IMP

Accomplishment

IMP

Milestone

Program /

Contract

Contract

Modification

Functional

Element

Logical

Element

Product

Element

Requirements

IPT

Functional

Work Package

CLINFunctional

Organization

Employee Cost

Cost

Other Direct

Travel

Deliverables

Process

Risk /

Opportunity

Risk / Opp

Cost

CDRL






Product Design


Product Realization

Industry

Value

Streams


Reporting and

Analytics

Requirements

Management

Model Based Systems

Engineering

AutomationDesign &

Commissioning

Mechanical Design

Model Based

Definition

End-item

Delivery (DD250 or

Airworthiness)

As-designed BOM

Management

MBOM and Bill of

Process


Safety

CAM / Tooling /

Fixtures

Assembly

Manufacturing

Engineering

Advanced

Aerostructure

Design

3D Electronic Work

Instructions

Material and

Compliance

Management

Technical

Publications

(S1000D)

Maintenance

Planning

Failure Reporting &

Corrective Action

Logistics Support

Analysis

Advanced

Manufacturing

As-Maintained

BOM

1D / 3D Simulation

and

Test Management

Plant

Design &

Optimization

Document

Management

(CDRL/SDRL)

Quality

Management

Manufacturing

Execution

Management

Supply

Chain

Collaboration

Software

Management

Electrical and

Electronics Design

Configuration and



Management

Part

Manufacturing

GSE/EGSE Design


Condition of Supply

Maintenance


3D Massive Model

Visualization

Capabilities

Manufacturing

Operations

Management

ERP

Integration

Software

Maintenance

Maintenance

Ergonomic

Analysis

Field Experience

Feedback

Obsolete

Management

Manufacturing

Optimization MRO

Integration



Innovation

Portfolio






Solution Description

• Change source selection from document manual process to electronic

requirements based

• Provide traceability to contract or company requirements

• Change supplier management from re-active ad-hoc to proactive process

based

• Integrate supplier schedules with program schedule

Since the Executive Council Meeting

• Initial process diagram complete

• Big Block diagram in work

• Ready for customer vetting






Product Design


Product Realization

Industry

Value

Streams


Reporting and

Analytics

Requirements

Management

Model Based Systems

Engineering

AutomationDesign &

Commissioning

Mechanical Design

Model Based

Definition

End-item

Delivery (DD250 or

Airworthiness)

As-designed BOM

Management

MBOM and Bill of

Process


Safety

CAM / Tooling /

Fixtures

Assembly

Manufacturing

Engineering

Advanced

Aerostructure

Design

3D Electronic Work

Instructions

Material and

Compliance

Management

Technical

Publications

(S1000D)

Maintenance

Planning

Failure Reporting &

Corrective Action

Logistics Support

Analysis

Advanced

Manufacturing

As-Maintained

BOM

1D / 3D Simulation

and

Test Management

Plant

Design &

Optimization

Document

Management

(CDRL/SDRL)

Quality

Management

Manufacturing

Execution

Management

Supply

Chain

Collaboration

Software

Management

Electrical and

Electronics Design

Configuration and



Management

Part

Manufacturing

GSE/EGSE Design


Condition of Supply

Maintenance


3D Massive Model

Visualization

Capabilities

Manufacturing

Operations

Management

ERP

Integration

Software

Maintenance

Maintenance

Ergonomic

Analysis

Field Experience

Feedback

Obsolete

Management

Manufacturing

Optimization MRO

Integration



Innovation

Portfolio





Current Verification Documentation is Segmented and Disconnected between

Virtual and Physical Environments

As-DesignedRequirements

Test Article

Build

Test Article

As-Tested

Test Data

As-Analyzed

Test Article

As-Analyzed

Test ProcedureTest Request

Test Planning

Test Execution

Virtual Physical

Test Article

Instrumentation


• Integrated requirements verification

management process

• Complete traceability of all artifacts

• Tie production eBOM to test article

eBOM for rapid change impact

awareness

• Manage test article configurations

• Ensure analysis models are based on

latest design model

Status

• Process diagram complete

• Big Block diagram complete

• Customer vetting complete

• V1.0 Catalyst deployed – customer

installed

• V1.1 Catalyst development –Release in

April

• Enhanced verification by analysis

• Supports A&D template – doc centric



Production

As-DesignedRequirements

Test Article

Build

Test Article

As-Tested


Closed Loop Requirements to Compliance – Qualification Digital Thread

Test Data

Production

As-Analyzed

Test article

As-analyzed

CORRELATE

Test ProcedureTest request

Test planning

Test Execution

Virtual Physical

Test article




Product Realization


Product Design


Product Realization

Industry

Value

Streams


Reporting and

Analytics

Requirements

Management

Model Based Systems

Engineering

AutomationDesign &

Commissioning

Mechanical Design

Model Based

Definition

End-item

Delivery (DD250 or

Airworthiness)

As-designed BOM

Management

MBOM and Bill of

Process


Safety

CAM / Tooling /

Fixtures

Assembly

Manufacturing

Engineering

Advanced

Aerostructure

Design

3D Electronic Work

Instructions

Material and

Compliance

Management

Technical

Publications

(S1000D)

Maintenance

Planning

Failure Reporting &

Corrective Action

Logistics Support

Analysis

Advanced

Manufacturing

As-Maintained

BOM

1D / 3D Simulation

and

Test Management

Plant

Design &

Optimization

Document

Management

(CDRL/SDRL)

Quality

Management

Manufacturing

Execution

Management

Supply

Chain

Collaboration

Software

Management

Electrical and

Electronics Design

Configuration and



Management

Part

Manufacturing

GSE/EGSE Design


Condition of Supply

Maintenance


3D Massive Model

Visualization

Capabilities

Manufacturing

Operations

Management

ERP

Integration

Software

Maintenance

Maintenance

Ergonomic

Analysis

Field Experience

Feedback

Obsolete

Management

Manufacturing

Optimization MRO

Integration



Innovation

Portfolio





Product Realization

Manufacturing to Engineering – Digital Thread


• Full end to end process

• Focus on driving manufacturing requirements into Concept to

Build

• Concurrent maturing of manufacturing processes, tooling,

plant layout with design maturity

• Simple effective as-engineered to as-built for delivery

assurance

• Closed loop process ensures continuous improvement

• Design reviews are not just of product but also manufacturing

processes, tooling, planning – drive concurrent development

Since the Executive Council Meeting

• Process diagram complete

• Big Block diagram complete

• Initial customer vetting complete






Product Design


Product Realization

Industry

Value

Streams


Reporting and

Analytics

Requirements

Management

Model Based Systems

Engineering

AutomationDesign &

Commissioning

Mechanical Design

Model Based

Definition

End-item

Delivery (DD250 or

Airworthiness)

As-designed BOM

Management

MBOM and Bill of

Process


Safety

CAM / Tooling /

Fixtures

Assembly

Manufacturing

Engineering

Advanced

Aerostructure

Design

3D Electronic Work

Instructions

Material and

Compliance

Management

Technical

Publications

(S1000D)

Maintenance

Planning

Failure Reporting &

Corrective Action

Logistics Support

Analysis

Advanced

Manufacturing

As-Maintained

BOM

1D / 3D Simulation

and

Test Management

Plant

Design &

Optimization

Document

Management

(CDRL/SDRL)

Quality

Management

Manufacturing

Execution

Management

Supply

Chain

Collaboration

Software

Management

Electrical and

Electronics Design

Configuration and



Management

Part

Manufacturing

GSE/EGSE Design


Condition of Supply

Maintenance


3D Massive Model

Visualization

Capabilities

Manufacturing

Operations

Management

ERP

Integration

Software

Maintenance

Maintenance

Ergonomic

Analysis

Field Experience

Feedback

Obsolete

Management

Manufacturing

Optimization MRO

Integration



Innovation

Portfolio





Digital Thread in Product Support Planning and Execution

Design and

Development

MaintainabilityReliability Supportability

Logistics Support

Analysis

Environment &

Operational

Requirements

Customer

Requirements

Training and Training

EquipmentSupply Support Technical Data

Maintenance

Plan

Personnel

Requirements

Support Equipment Infrastructure

Support Concept

Testability



The Digital Enterprise

Connecting Manufacturing to Engineering

Digitalization Cornerstones

• A Digital Enterprise uses transformative technologies to

drive significant improvements in efficiency and agility

• The Siemens Digital Enterprise Suite is built on class-

leading PLM, MOM & Automation portfolios

• The Teamcenter Collaboration platform underpins the

Digital Enterprise and :

• Drives inter-departmental collaboration

• Synchronizes Suppliers and Customers

• Coordinates the network of production facilities

• The rock-solid, bulletproof automation technology for

Speed, Reliability, Safety, Security and Sustainability

+



Digital Enterprise Software Suite -

The Siemens answer to Industry 4.0 requirements



Summary

• Digital Twin provides virtual verification of the

product and process

• Digital Thread ties critical information to its inputs,

processes and outputs

• Siemens provides a unique solution set for

Industrie 4.0 and the digital-thread / digital-twin

• Siemens is a hardware manufacturing company

using our solutions to deliver customer value

digital twin digital thread in aerospace - siemens plm ... support a model based enterprise, digital...

Documents