presentation to the last frontier: eliminating the manufacturing bottleneck presentation to sme...
TRANSCRIPT
The Last Frontier:
Eliminatingthe
Manufacturing Bottleneckpresentation topresentation to
SME Automation Rendez-vousConference 2009
October 20, 2009OpenAire Inc. Logicap Engineering
Outline
1. OpenAire Background
2. The Manufacturing Bottleneck
3. Lean Stage 1: Automated Design
4. Results of Organizational Transformation
5. Lean Stage 2: Automated Welding
Company Overview
Founded in 1992
Marketing custom glass-aluminum retractable roof buildings globally
Recognized the manufacturing bottleneck in Year 2000
Began implementing Lean engineering
OpenAire Background
Water Parks
Resorts & Water Parks
OpenAire Background
Curved Retractable Roof Systems
OpenAire Background
Pre-Lean Practices
Sales Quotes relied on past experience Visuals generated by Engineering
Design 2D electronic drafting Manual material take-off
Manufacturing Frequent engineering changes 1,000s of hours of manual welding per building
OpenAire Background
Custom Manufacturing Process Flow
Time
Sales ProductionOrder Entry Purchasing
Applications Engineering
Design Engineering
Manufacturing Engineering
The Manufacturing Bottleneck
= critical path limiter
Bottleneck Functions
Applications Engineering Preliminary Bill of Materials & Process Plan Quote drawing and costing
Design Engineering Detailed Bill of Materials Fabrication & assembly drawings
Manufacturing Engineering Process Plan CNC programs
The Manufacturing Bottleneck
Why is Engineering a Bottleneck?
Most routine engineering work is delivered through time-consuming,
error-prone manual processes.
Bottleneck Consequences
Delay Sales prospects impatient for pricing Unpredictable delivery schedules
Error Engineers must remember 3D relationships
between components in different 2D drawings
Cost Engineering resources are expended in routine,
repetitive work Design errors usually result in shop floor waste
The Manufacturing Bottleneck
Preparation for Automated Design
Formalized design process as a series of inputs and validations
Wrote design rule algorithms
Created 3D parametric solid CAD template models
Installed multiuser web-based knowledge engine
Lean Stage 1: Automated Design
Automated Design Environment
Lean Stage 1: Automated Design
Web-basedKnowledge
Engine
Web-basedKnowledge
Engine
SQL Database
SQL Database
AuthoringTools
AuthoringTools
InterfaceInterface
Output Generators
Output Generators
CAD Templates
CAD Templates
ERPLink
ERPLink
Automated Design Functionality
1. Submit inputs defining the building and its features
2. Review ‘working line’ pictorials
3. Generate CAD assemblies
4. Generate B.o.M. & drawing layouts
Lean Stage 1: Automated Design
… then use interactive CAD to tweak the 3D assembly and annotate drawings.
Project HistoryGeneral Building Layout
Lean Stage 1: Automated Design
Structural Layout
Lean Stage 1: Automated Design
Truss Configuration
Lean Stage 1: Automated Design
Truss Group & Bracing Layout
Face Configuration
Lean Stage 1: Automated Design
Main Back Side(Gable, dimensions in inches)
Working Lines Review
Lean Stage 1: Automated Design
FrontBack
Right
Left
Detailed CAD Digital Prototype
Typical Building
110’ x 100’ x 32’
Design Review
Truss Group
Column Truss
Retractable Slider
Lean Stage 1: Automated Design
Curtain Wall Corner Detail
Web Browser 3D Model
Visualization &Installation Guide
Lean Stage 1: Automated Design
Assembly Structure with P/Ns
Atomic Bill of Materials
Lean Stage 1: Automated Design
Bill of Materials -- Salinas SME Project
Item Qty Part Number Description Material Length Cut Width Thickness1 16 630~EH05640~016 Brace Tube x H1.5 x W1.5 x T0.188 x L16.971 Aluminum 6063-T6 16.97056 0 02 104 630~EH05640~017 Brace Tube x H1.5 x W1.5 x T0.188 x L16.971 Aluminum 6063-T6 16.97056 0 03 16 630~EH05640~018 Brace Tube x H1.5 x W1.5 x T0.188 x L16.971 Aluminum 6063-T6 16.97056 0 04 20 630~EH05810~008 Brace Tube x H2 x W2 x T0.188 x L20.651 Aluminum 6063-T6 20.65149 0 05 20 630~EH05810~009 Brace Tube x H2 x W2 x T0.188 x L21.583 Aluminum 6063-T6 21.58253 0 06 20 630~EH05810~007 Brace Tube x H2 x W2 x T0.188 x L22.576 Aluminum 6063-T6 22.57587 0 07 20 630~EH05810~013 Brace Tube x H2 x W2 x T0.188 x L24 Aluminum 6063-T6 24 0 08 20 630~EH05810~006 Brace Tube x H2 x W2 x T0.188 x L25.072 Aluminum 6063-T6 25.07173 0 09 20 630~EH05810~010 Brace Tube x H2 x W2 x T0.188 x L25.157 Aluminum 6063-T6 25.15671 0 010 20 630~EH05810~005 Brace Tube x H2 x W2 x T0.188 x L27.805 Aluminum 6063-T6 27.8047 0 011 20 630~EH05810~004 Brace Tube x H2 x W2 x T0.188 x L30.797 Aluminum 6063-T6 30.79729 0 012 20 630~EH05810~003 Brace Tube x H2 x W2 x T0.188 x L34.074 Aluminum 6063-T6 34.07419 0 013 20 630~EH05810~002 Brace Tube x H2 x W2 x T0.188 x L37.662 Aluminum 6063-T6 37.66238 0 014 320 630~EH05810~011 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 015 20 630~EH05810~012 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 016 20 630~EH05810~014 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 017 20 630~EH05810~015 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 018 20 630~TBD~001 Brace Tube x H4 x W4 x T0.5 x L36.018 Aluminum 6063-T6 36.01787 0 019 28 630~844987~002 Center Mullion Cap x L307.94 Aluminum 6063-T6 307.94018 0 020 28 630~844987~003 Center Mullion Cap x L313.86 Aluminum 6063-T6 313.86 0 021 8 630~844987~001 Center Mullion Cap x L626.065 Aluminum 6063-T6 626.06518 0 022 28 630~844986~002 Center Mullion x L308.128 Aluminum 6063-T6 308.12768 0 023 28 630~844986~003 Center Mullion x L316 Aluminum 6063-T6 316 0 024 8 630~844986~001 Center Mullion x L626.253 Aluminum 6063-T6 626.25268 0 025 20 630~p- CBG~001 Column Base Gusset x T0.25 x W6 x L14.04 Aluminum 6061-T6 14.04002 6 0.2526 20 630~p- CF~001 Column Foot Plate x T0.5 x W14 x L20 Aluminum 6061-T6 20 14 0.527 10 630~896139~003 Curtain Wall 3- 5/8" x L130.27 Aluminum 6063-T6 130.2705 0 028 99 630~896139~009 Curtain Wall 3- 5/8" x L135.938 Aluminum 6063-T6 135.9375 0 029 2 630~896139~005 Curtain Wall 3- 5/8" x L138.15 Aluminum 6063-T6 138.1505 0 030 2 630~896139~030 Curtain Wall 3- 5/8" x L138.15 Aluminum 6063-T6 138.1505 0 031 35 630~896139~032 Curtain Wall 3- 5/8" x L14.749 Aluminum 6063-T6 14.749 0 032 1 630~896139~001 Curtain Wall 3- 5/8" x L14.782 Aluminum 6063-T6 14.78159 0 033 1 630~896139~028 Curtain Wall 3- 5/8" x L14.782 Aluminum 6063-T6 14.78159 0 034 6 630~896139~011 Curtain Wall 3- 5/8" x L144.124 Aluminum 6063-T6 144.12404 0 035 6 630~896139~023 Curtain Wall 3- 5/8" x L144.124 Aluminum 6063-T6 144.12404 0 036 13 630~896139~006 Curtain Wall 3- 5/8" x L19.499 Aluminum 6063-T6 19.499 0 037 18 630~896139~037 Curtain Wall 3- 5/8" x L26.59 Aluminum 6063-T6 26.59001 0 038 1 630~896139~002 Curtain Wall 3- 5/8" x L29.541 Aluminum 6063-T6 29.54082 0 039 1 630~896139~029 Curtain Wall 3- 5/8" x L29.541 Aluminum 6063-T6 29.54082 0 040 2 630~896139~015 Curtain Wall 3- 5/8" x L34.022 Aluminum 6063-T6 34.02226 0 0
Accurate Drawings
Applications Engineering, time Preliminary building designs and costs
generated automatically on demand
Manufacturing Engineering, n/c The next Lean target, Stage 2
Design Engineering, time Detailed Bill of Materials and accurate shop
drawing layouts extracted automatically from the 3D CAD building prototype
Impact on Manufacturing Bottleneck
Results of Organizational Transformation
Positive Trends
Results of Organizational Transformation
Customer Service
Product Quality
Profitability
Growth
Costs
Quoting Improved customer response Reduced demand for engineering resources
Design for production Estimated 50% time savings in engineering Custom truss designs replicated digitally
Manufacturing New confidence in engineering drawings
Measurable Improvement
Results of Organizational Transformation
Ready for the Next Lean StagePast Investigations
A prerequisite for eliminating thefinal manufacturing bottleneck is
custom truss designsare replicated digitally.
Robotic weld programming Too time-consuming using truss designs
developed by 2D electronic drafting processes
Weld fixturing Precision positioning of long, extruded sections
is difficult so ‘ideal-path’ weld motions must be corrected for component warpage
Cost justification Existing robotic approaches could not compete
with current manual methods
Lean Stage 2: Automated Welding
New Developments
Robotic weld programming now feasible because … Automated design generates 3D geometry
suited to automated weld path extraction Fixturing demands are relaxed with tip-touch
system correction of CAD-to-actual weld path
Cost justification Will depend on price/performance of proposed
system relative to current manual methods
Lean Stage 2: Automated Welding
Digital Weld Path Extraction
Lean Stage 2: Automated Welding
Deviation of Actual from Digital
Lean Stage 2: Automated Welding
Weld path corrected by tip-
touch system
Path variability due to fixturing
limitations
Next Steps
Review welding machine builders Need system to fixture components for large,
variable size trusses quickly and accurately
Generate CNC code from 3D model Need algorithms to extract weld paths and tip
angles from relevant geometry faces
Cost justification Final decision to proceed with Lean Stage 2
dependent on projected savings
Lean Stage 2: Automated Welding
IN SUMMARY
The custom manufacturing bottleneck:
Is caused by routine manual engineering
Can be eliminated through design automation
Must be eliminated before welding automation is cost-justifiable
THANK YOU
Contact
Mark AlbertineOpenAire Inc.2360B Cornwall RoadOakville, Ontario Canada L6J 7T9Tel. (905) 901-8535Email [email protected]
Gord HobbsLogicap Engineering Corp.
#9 - 140 McGovern DriveCambridge, Ontario
Canada N3H 4R7Tel. (519) 489-7222
Email [email protected]