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VFF NEWS Issue 3; October 2011 2
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Editorial Marco Sacco ITIA-‐CNR
VFF project is now at the beginning of its third year of work. The partners worked hard for answering at t h e i n d u s t r i a l requirements and to find out appropriate t e c h n i c a l a n d t e c h n o l o g i c a l soluLons for making t h e i r a n s w e r s feasible.
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VFF is a big project and having 30 partners collaborate and communicate was a hard work. In this issue of the VFF newsleMer all the modules are described. In the image up here the modules have their place in the factory process. Discover in the next pages the meaning of the Ltles here on leQ.
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1 Control Station for Production fine planning PSI The PSI Planning Board is a soluLon for producLon planning and scheduling tasks. It combines powerful scheduling funcLonality with a customable and easy to use GUI. The module is easy to use and integrates seamless to an exisLng environment.
DAM: Dysfunction Analysis Module UTCN This module aims at gathering, filtering, a n a l y z i n g a n d e l a bo r aLng d a t a related to machine failures and repair acLviLes. The main objecLve of DAM is to s u p p o r t t h e p e r f o r m a n c e improvement of a producLon system, in parLcular during the ramp-‐up phase.
• Easy and fast chart/report generaLon, no manual work
• DrasLcally reduced Lme for the enLre analysis process
• Improved producLon system performance
BENEFITS • Automated process for
failure analysis • Integrated fa i lure
results accessible by one tool
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BENEFITS • OpLmal resource usage in
so lv ing fin i te schedul ing problems
• Ov e r v i ew b y g r a p h i c a l representaLons for planning situaLons in real Lme
• IntegraLon of producLon process by interfaces to ERP and shop floor control systems
The module provides decision support concerning the selecLon of alternaLve producLon line configuraLons. The module takes into account the criteria (KPIs) that have been esLmated for each alternaLve configuraLon and proposes a line that can be considered as the best alternaLve with respect to the specified criteria. The module incorporates normalizaLon of the criteria and a weighLng factors methodology in a user friendly environment.
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1 Decision Support LMS-‐CASP
BENEFITS • Simple and effecLve decision making based
on KPIs • SystemaLc evaluaLon of producLon line
alternaLves
DSM: Design Synthesis Module UTCN The main objecLve of this module is to improve the Proposal and Design&Development processes and at the same Lme to facilitate and fasten up the work of the departments involved in these business phases.
• Speed up the definiLon/evaluaLon of the producLon resources
• Enable quick reuse of data (other proposals, other projects), easy adjustments of the proposals
• Shorten the Lme needed today for proposal phase
BENEFITS • Avoid using the exisLng excel files • Avoid having so many manual computaLons • ParallelizaLon of the work for several departments • Enable concurrent design, integraLon with other
tools
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1 EUVEDES EUVE TECNALIA
It’s the applicaLon of EUVE discrete event simulator for producLon line, with the goal of thinking the factory as a product. Via simulaLons and trials, the user can determine the best approach to improve efficiency, throughput and energy consumpLon of the line in order to determine the best design of it.
BENEFITS • Friendly interface • Easy to be used • New features different from the
exisLng tools that are linked to t h e p r o du cLon p l a n n i n g generaLon tools.
FLP: Factory Layout Planning ICIMSI
The FLP is a mulL-‐client -‐ server applicaLon that supports collaboraLve factory layout planning. Planners located at different remote sites can collaborate at the same Lme on the same layout. FLP allows to construct a 3D model of the building and to define points of availability of the plant services (electricity, pressurized air, etc.). FLP enables a “what if” analysis of the system performances using a discrete events simulaLon (DES) engine.
BENEFITS • Easy configuraLon and reconfiguraLon of producLon based on user friendly intuiLve drag & drop interface • Real-‐Lme plant redefiniLon from different actors and different locaLons • Discrete events simulaLon capabiliLes of the FLP will foster layout performance staLsLcs gathering.
Giove VF ITIA-‐CNR
FP3 is a VFF module for the monitoring and evaluaLon of technical performance indicators (inventory capacity, efficiency, etc.) and economic performance indicators (profitability, payback Lme, etc.). Further it is used for process, equipment and layout planning.
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1 FP3 IPA BENEFITS • Improved approximated value of life
cycle costs as well as technical performance of producLon faciliLes
• Forecast funcLon for idenLficaLon of savings or addiLonal costs at an early planning phase
• Methodical procedure • Easy and quick imaging of alternaLve
planning scenarios
GIOVE Virtual Factory is a virtual collaboraLve environment aimed at supporLng the factory layout design. Machines, operators and other resources can be selected from a library and placed in the 3D scene. The environment can display performance measures that are provided by simulators and/or monitoring tools.
BENEFITS • IntuiLve interface • Building and producLon
resources can be added/moved/removed
• Di rec t co l l aboraLon among two or more users sharing the same Virtual Environment
• Voice conference control and automaLc messaging can be enabled via Skype
The iDecisionSupport (iDS) Module is a collaboraLve decision making environment, accessible via web-‐browsers, where team members aMend do different types of decisional meeLngs.
iDecision ROPARDO
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1 HIL: Hardware in Loop FATRONIK TECNALIA The planning of a new factory or the update an exisLng one requires to use the most accurate process and machine performance data. Therefore, why not join the Discrete Event SimulaLon with a Hardware In the Loop simulaLon? In such a way, we will have the best of two worlds, we can simulate the whole factory and simulate criLcal points in detail.
BENEFITS • Analysis of the strong
interrelaLon of internal variables on stochasLc mulL-‐s t e p , mu l L -‐ r e f e r e n c e industrial scenarios
BENEFITS • Easily access remotely and
asynchronously • NoLficaLon via e-‐mails • AutomaLcally Protocols
generated and sent via email
• Simple acLons like grading an issue or expressing the agreement
• Support synchronous and asynchronous collaboraLon
• Reduce Lme for Decision
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1 IMPACT LMS BENEFITS • I n te l l i gent opLmizaLon o f
producLon systems scheduling • Task allocaLon to the most
suitable resources
IPS:Interactive Projection System CEIT
IPS represents an integrated concept for intuiLve team-‐oriented factory planning. It contains tools for layout design and opLmizaLon, material flow and transport routes opLmizaLon.
BENEFITS • AcceleraLon and opLmizaLon of
the planning process (layout planning).
• Layout and mate r i a l flow opLmizaLon.
• 3D visualizaLon. • Physics simulaLon • Collision detecLon
The Intelligent Manufacturing Planning And Control Tool (IMPACT) is responsible for producLon scheduling and process planning. It considers resources and tasks simultaneously and can assign each task to a specific resource while taking into consideraLon mulLple criteria which can be defined by the user.
• Reduced cost and Lme for producLon scheduling
• Automated generaLon of alternaLve scheduling soluLons and evaluaLon.
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1 iPortal ROPARDO
iPORTAL Virtual Factory is a virtual locaLon with a dashboard-‐like interface integraLng different modules and therefore, offering the user a central informaLon point for distributed and collaboraLve working environment.
PMD is a soluLon designed to support performance measurement, in the most reliable way, in order to feed performance management systems. It provides the means to store, organize and analyse large volumes of data in order to allow the performance of simple and understandable analysis as well as give measurements that empower managers decisions.
BENEFITS • MulL Source and Data Fusion Features • Fast and Accurate ReporLng through
Extensible Dashboard SoluLon • Quick KPI calculaLon with low resources • Eliminate redundancy • Fully Scalable • Support Development of Performance
ForecasLng tool
BENEFITS • Increase the collaboraLve work (email,
message-‐board, Skype, agenda) • Support for File Management • Effi c i e n t a n d e ff e c L v e d a t a
management • Knowledge Repository (wiki) • IntegraLon with other web tools • Access the external data bases
PMD: Performance Measurement Dashboard INESC
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1 PLM SPF
Used in steel fabricaLon, PLM handles producLon management from material purchase to shipping. It breaks down CAD drawing imports to elementary work-‐orders that can be sent to CNCs. The operator can perform scheduling, based on imported and refined shop floor layout, provisional execuLon Lmes and context-‐sensiLve best path computaLon. A strong factory feedback ensures monitoring and dynamic adaptaLon of parameters.
BENEFITS • Lower producLon
Lmes • BeMer
workstaLon saturaLon
• BeMer throughput
• Overall producLon Lme opLmizaLon .
PROD SIM SZTAKI
BENEFITS • Off-‐line analysis in the design phase • On-‐line analysis during the operaLonal phase • The simulation models are built and parameterized upon a totally automated way thus could be
referred to as a self-building simulation system.
The ProducLon SimulaLon is based on TecnomaLx Plant SimulaLon (PS) SW. The VF Manager provides the versioning of different simulaLon model files (mirroring the different states of the producLon system), while the module enables the real-‐Lme database connecLon to the Factory Image database where all the simulaLon data are collected (ERP, SCADA, OPC server) and required for the simulaLon experiments.
The RDV provides a flexible graphical user interface of the producLon related data and the simulaLon experiments result. It’s as a simulaLon cockpit with which simulaLon experiments are iniLated and maintained. MulL-‐user funcLonality is strongly supported.
RMP: Requirements Management & KPI Planning ETHZ NOVA
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1 RDV: Reporting Data Visualization SZTAKI BENEFITS • All-‐in-‐one cockpit applicaLon for
discrete event simulaLon (DES) experimentaLon and producLon data analysis.
• Plaiorm independent, can be aMached to any other VF Modules encapsulaLng DES
The RMP Tool aims at linking the intenLon of all involved stakeholders with an accurate and tailored performance measurement. The approach bases on a network of funcLonal requirement specificaLon for new producLon systems.
BENEFITS • SpecificaLon of factory funcLons • Stakeholder-‐driven goal modeling capabiliLes • IdenLficaLon and mapping of KPIs and resources • Set-‐up of target system for performance measurement • Embedding sustainability aspects explicitly
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SAVCP: Site & added value chain planning WZL
VC: Visual COmponents SimX
Visual Components is a one of the leading soQware products for the modelling (in 3D) and simulaLon of complete manufacturing systems. The most important features of VC are the possibility of performing material flow and roboLc simulaLon on the same plaiorm, authoring components in order to create a library of re-‐usable equipment, open architecture and enhanced connecLvity through Windows COM and Python APIs.
BENEFITS • Provide valuable informaLon about logisLcs,
operaLonal details of Material Handling Systems and Equipment, process planning, resource definiLon and allocaLon, line balancing, equipment and workplace planning, manual procedures, ergonomic assessments and planning, Health & Safety ExecuLve (HSE) records, automaLon and control Planning, factory KPIs.
The Site and Value-‐added Chain Planning Module enables the configuraLon and opLmizaLon of a site with its value-‐added chain. It uses the criteria costs and lead Lme in order to find the opLmal producLon scenario.
BENEFITS • Quick evaluaLon of value-‐added chain • Flexible input of process steps • InteracLve adaptaLon of data and fast
generaLon of new scenarios
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1 WITNESS LMS
WITNESS is an established dynamic process simulaLon tool used by thousands of organisaLons to validate a proposed facility or business process, to achieve a desired
BENEFITS • IntegraLon of a commercial DES
SW with the VF Manager
PotenLal failure modes and Effects Analysis (PEA) is a web tool that facilitates analysis, data management and reporLng for FMEA. The PEA Module permits the rapid entry of data and also check of the exisLng data from past projects using pop-‐up dialogs which may be accessed simply by clicking on the buMon.
BENEFITS • CollaboraLve work • CBR soluLon integrated • Reuse Engineer’s know-‐how • StaLsLcs with most important failure
modes, effects and causes • Reduce the Lme of this procedure • Support mulLple users by leveraging
a Web interface • AutomaLc criLcality calculaLons
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PEA: Potential Effects Analisys ROPARDO
process performance metric or to support conLnuous process improvement acLviLes. The connector developed by CASP and LMS allows the uLlizaLon of this commercial DES tool within the framework of VF Manager.
Requirements Management Workflow (RM Workflow) is a web and an intuiLve tool that facilitates the flow of informaLon, tasks and events. The RM Workflow engines interpret the documents in the server and acts according to the computer defined process.
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1 RM Workflow: Requirements Management ROPARDO
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BENEFITS • Supports the collaboraLon
between the members • NoLficaLon via e-‐mails with the
status of documents • Easi ly accessing the r ight
informaLon depending on given access rights
• Access to the last version of documents
• Easy to track the status of started projects
• Provides conceptual integraLon of business
Visit www.vff-project.eu to keep updated about VFF modules and to have further information
Follow VFF Virtual Factory on twitter
Watch video about VFF industrial scenario on VFF web and youtube
Join VFF group on LinkedIn
Visit VFF web site www.vff-‐project.eu
Edited by ITIA-‐CNR Text by VFF consorLum If you want to receive the NewsleMer directly in your mail box write an e-‐mail to: info@vff-‐project.eu