Program Summary

1
SAVE
OMG Manufacturing DTF Meeting Marcia
Herndon marcia.f.herndon_at_lmco.com
2
Agenda

• Program Overview
• Technical Approach
• SAVE Simulation Tools
• SAVE Data Model
• Summary

3
The Vision
Making Virtual Manufacturing A Reality

• Virtual manufacturing simulations will improve
  product affordability by
• Identifying better product/process alternatives
• Solving potential manufacturing problems early in
  design
• Reducing scrap, rework, repair, and redesign
• Integration of manufacturing simulation tools is
  necessary to make their use timely and affordable

4
Concept of Operation

• Facilitates Concurrent Engineering in an IPT
  environment
• Provides high fidelity assessment of
  manufacturing impacts of design decisions
• Choice of tools tailored to problem
• Integrates design, manufacturing, systems
  engineering, and cost
• Affordability benefits achieved by applying
  Manufacturing Modeling and Simulation tools
• SAVE integration enables widespread use of these
  tools

5
SAVE Impact

• Identify better product and process design
  alternatives
• Reduce redesign
• Reduce scrap, rework, and repair
• Improve trade study cost estimation accuracy
• Reduce first article cost and improve learning
  curve
• Reduce fabrication and assembly inspection
• Increase inventory turns

6
Technical Approach
CORBA Distributed Network Computing Layer
CAD
Factory Simulation
Virtual Assembly Planning
Schedule Simulation
Cost Models
Risk Analysis Models
Assembly Variability Simulation
Work Flow Manager
SAVE Data Model
Query Manager
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SAVE Tools

• Accurate Simulation of Manufacturing Processes
• Dynamic Simulation Model Creation
• Produces Time Estimates
• Provides Animated Work Instructions

• Loosely Coupled
• Part and Tool 3D Models
• Direct Links with CA and VSA 3D

• Statistical Analysis of Tolerance Build-up
• Ranks Contributors
• Identifies Optimal Assembly Order

• Discrete Event Simulation
• Highly Visual
• Dynamic Simulation Model Creation
• Identifies Bottlenecks

8
SAVE Tools

• Knowledge Based Tool
• Models are Process and Feature Based
• Direct Feature Extraction from CAD
• 4 Models Assembly, Sheet Metal, Composite,
  Machined Parts

• Model Problems in Spreadsheet-Like Tool
• Rigorously Treats Uncertainties
• Partially Automated Model Construciton
• Calculates Probability of Achieving Results

• Discrete Event Simulation
• Impact of Production Rate on Resources
• Produces Schedule from Simulation Results

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Work Flow Manager

• Graphically models a process with decomposition
  down to the activity level
• Defines dependency relationships among components
  of the process
• Executes the process
• Sends messages to users and tools
• Monitors progress/status
• Provides graphical feedback
• Implemented in JAVA for platform independence
• Communicates with simulation tools via CORBA

10
SAVE Query System

• Provides visibility into the SAVE data
• Provides capability to
• Browse objects /attributes
• Create objects /attributes
• Modify objects /attributes
• Delete objects /attributes
• Implemented in JAVA for platform independence
• Communicates with the SAVE data model via CORBA

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Examples of SAVE Common Data
Factory Simulation
Assembly Planning
Variation Analysis
Enterprise Optimization
Schedule Simulation
Risk Analysis
Cost Analysis
CAD
Process Plan / Work Inst Geometric Models /
Defn Task Durations Resource Estimates Rates and
Factors Process Rates Factory Layout /
Definition Manufacturing Rules Timelines Feature
Definitions Cost Tolerance Limits Risk
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SAVE Data Model

• Inputs from Numerous Sources
• Manufacturing Engineers
• Design Engineers
• Simulation Software Vendors
• Simulation Software Users
• Previous Studies
• Includes Three Types of Data
• Common Data Process, Resource, and Product
• Assessment Data Cost, Schedule, and Risk
• Model Management Data
• Proven to be Quite Robust
• Used in 2 Pilot Exercises
• Used in 2 Beta Tests
• Reviewed by Wide Variety of Organizations

13
SAVE Data Model Statistics

• Defined Using CORBA IDL
• Contains 39 Top-Level Interfaces
• All But 1 Interface is Made Persistent
• All Interfaces Inherit from Either Base Object or
  Named Object
• Base Object Contains an Object Type Attribute
• Named Object Contains Name, Description, and
  Date/Time Attributes

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SAVE Model Management DataLibrary
Provides user access to all of the instances of a
specific type of object.

• List of Library Objects
• Break
• CAD Model
• Design Alternative
• Design Study
• Inflation Table
• Material
• Manufacturing Program
• Part
• Name Name of the library. Set to the type of
  object in the library.
• Description Description of the library.

• Personnel
• Process Plan
• Reference Process
• Simulation Request
• Tool
• Work Calendar
• Work Shift

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SAVE Model Management DataDesign Study (Library)
Provides a container for the data associated with
a manufacturing design or trade study. It
includes evaluation of one or more alternatives
with respect to specific variables.

• Name Name of the study.
• Status Defines the status of the study for
  configuration management purposes (working,
  review, released).
• Design Alternatives Set of one or more design
  options for a given study.
• Selected Alternative Option deemed to be the
  most desirable in terms of the criteria defined
  for the study.

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SAVE Model Management DataDesign Alternative
(Library)
Defines an approach to a design or process
decision.

• Name Name of the alternative.
• Status Defines the status of the alternative
  for configuration management purposes (working,
  review, released).
• Process Plans List of optional process plans
  associated with a particular design alternative.
• Baseline Process Plan Plan deemed to be the
  most desirable in terms of the criteria defined
  for the overall study.
• Manufacturing Program Manufacturing program for
  which the alternatives apply (e.g., F-22, F-16).

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SAVE Model Management DataSimulation Request
(Library)
Provides entry pointers for client access into
the model. Contains the object reference for the
design study, design alternative, and process
plan required for a particular client.

• Process Plan Object reference to the process
  plan for which a simulation is to be run.
• Input Options Defines the input options that
  should be exercised when the simulation code
  begins its read transaction.
• Output Options Defines the output options that
  should be exercised when the simulation code
  begins its write transaction.

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SAVE Model Management DataDatabase Access
Provides the operations (methods) that control
access to the data in the model. This includes
read and write transactions, commits and
rollbacks, and create and copy objects.

• Not made persistent in data store.
• Allows multiple read transactions at one time.
• Allows one write transaction at a time.
• Provides commit and rollback capability.
• Provides access specifically to library objects.
• Allows creation of named objects within the
  model.
• Provides for intelligent object copies.

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SAVE Core Process DataProcess Plan (Library)
Defines how a product is manufactured. Contains
an ordered list of operations or job steps that
define that manufacturing process.

• Status Flag Indicates working, review or
  released for configuration management.
• Bill of Materials Indentured parts lists that
  define the manufacturing sequence and usage of
  parts.
• Cost Overall costs associated with the plan.
• Schedule Overall schedule for completing the
  plan.
• Risk Risk associated with the plan.
• Resource Pool Personnel and tool resources that
  are available to complete the process plan.
• Operation Ordered list of job steps required to
  manufacture and/or assemble the parts in the plan.

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SAVE Core Process DataOperation
Defines a specific operation (process) or step
within a process plan. For generality, an
operation may itself be a process plan.

• Reference Process Contains standard process
  information (e.g., historical hours and risk
  values) for the operation.
• Precedents Defines the operations which must be
  complete prior to starting the operation.
• Resource Application Personnel or tool
  resources used in the operation.
• Consumed Parts List of parts used in the
  operation.
• Produced Parts List of parts produced by the
  operation.
• Run Time Number of hours to complete the
  operation.
• Cost Costs associated with the operation.
• Schedule Start and end dates associated with
  the operation.
• Risk Process capabilities associated with the
  operation.

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SAVE Product DataPart (Library)
Defines a specific operation (process) or step
within a process plan. For generality, an
operation may itself be a process plan.

• Type Specifies whether the part is a detailed
  part or assembly.
• Number Part number identifier.
• Associated Parts List of parts in the part if
  it is an assembly.
• Features Features modeled in the part.
• Name Name of the part.
• Material Material used to produce the part.
• Cost Cost breakdown for the part.
• CAD Model CAD models associated with the part.
• Other Associated Objects
• Part Usage Quantity of the part used in a given
  operation.
• Part Location Location of the part in the
  factory as it is used in a given operation.

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SAVE Product DataFeature
Defines design or manufacturing part features.

• Name Name of the feature.
• Quantity How many of the feature are in the
  part.
• Cost Costs associated with the feature.
• Type Defines the kind of feature (e.g., base
  part, hole, slot)

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SAVE Product DataMaterial (Library)
Defines the materials that are used in producing
parts.

• Name Name of the material.
• Unit Cost Cost of the material in dollars per
  unit (e.g., dollars per pound).
• Type Specific material type (e.g., Titanium
  6-4, Aluminum 2024).
• Form Form for the raw material (e.g., bar,
  sheet).

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SAVE Resource DataPersonnel (Library)
Defines the categories of personnel resources
available to the production activity.

• Skill Defines the personnel skill category
  (e.g., welder, mechanic).
• Shift Defines the work shifts for this
  personnel type.
• Calendar Defines the work days for this
  personnel type.
• Labor Rate Defines the personnel cost in
  dollars per hour.
• CAD Model Points to the CAD model for this
  resource.
• Efficiency Defines an efficiency factor to
  apply to the available usage.
• Other Related Objects
• Resource Pool Defines the quantity of a
  personnel skill type that is available to the
  process plan. Also tracks utilization.
• Resource Application Defines the location and
  quantity of a personnel resource used in a given
  operation.

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SAVE Resource DataTool (Library)
Defines the categories of tool resources
available to the production activity.

• Name Name of the tool that conveys its type
  (e.g., fixture).
• Type Type of tool for simulation purposes
  (e.g., moveable, stationary).
• CAD Model Points to the CAD model for this
  resource.
• Efficiency Defines an efficiency factor to
  apply to the available usage.
• Tolerance Defines the tolerance capability of
  the tool.
• Cost Cost to make or buy the tool in dollars.
• Other Related Objects
• Resource Pool Defines the quantity of a tool
  type that is available to the process plan. Also
  tracks utilization.
• Resource Application Defines the location and
  quantity of a tool resource used in a given
  operation.

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SAVE Assessment DataCost
Defines the basic set of cost data used
throughout the model.

• Basic Cost Categories
• Recurring Manufacturing Labor
• Material
• Quality Assurance
• Development Tooling
• Production Tooling
• Nonrecurring Tooling
• Tool Material
• Type Type of costs being stored (e.g., First
  Unit, Average, Total).
• Fiscal Year Year for which the costs are
  estimated.
• Base Year Year for which inflation values are
  1.0.

• Sustaining Tooling
• Plant Equipment
• Other Recurring
• Other Nonrecurring
• Total Manufacturing
• Average Production

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SAVE Assessment DataSchedule
Defines the basic set of schedule data used
throughout the model. This object references
calendar time not labor hours.

• Planned Duration Planned duration for a task in
  hours.
• Actual Duration Actual duration for a task in
  hours.
• Planned Start Date Planned starting calendar
  date for a task.
• Planned End Date Planned ending calendar date
  for a task.
• Actual Start Date Actual starting calendar date
  for a task.
• Actual End Date Actual ending calendar date for
  a task.
• Priority Priority of the scheduled item - low,
  medium, high.

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SAVE Assessment DataRisk
Defines the basic set of risk data used
throughout the model.

• Name Type of risk object being stored (e.g.,
  overall, tolerance).
• Yield Percentage of correct results produced by
  the process.
• Failure Probability Likelihood of the failure
  of a given activity as percentage defects.
• Mean Mean value of the risk distribution.
• Standard Deviation Measure of the dispersion of
  a frequency distribution with respect to the
  mean.
• Cp and Cpk Process capability measurements.
• Contributors List of the contributing factors
  to the risk and their percentage contribution.

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Key Findings from Use of SAVE3 Pilot
Demonstrations and 2 Beta Tests Over 4 Year
Program

• Data Model is Stable and Robust
• Current Tool Categories Use Common Data, But Only
  Originate a Subset of It
• Process Planning Tool is Necessary to Generate
  Initial Set of Data
• System Installation Must Be Well-Defined and
  Tested
• Users Must Understand the Data Model As Well As
  the Vendor Tool Capabilities/Limitations

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SAVE Status

• Successful Interim Demonstration performed in
  August 1998 and again at Defense Manufacturing
  Conference in December
• System beta tested at LMTAS and Boeing
• Response to OMG MfgDTF RFI 4 with IDL
  representation of SAVE Data Model
• Final cycle of system enhancements complete
• F-22 weapons bay door demonstration scheduled for
  Sept 1999
• Commercialization prospects are excellent
• More information available on the SAVE web site
  at skipper.mar.external.lmco.com/save