Swee Leong

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2004 Fall SIW Special SessionModeling
Simulation for Engineering and Manufacturing

• Swee Leong
• Leong_at_nist.gov
• 301-975-5426
• Manufacturing Systems Integration Division
• National Institute of Standards and Technology
• Gaithersburg, MD
• USA

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Topics

• Background
• Manufacturing Simulation Applications
• Simulation Problem Summary
• Simulation Standards Opportunities
• Example Projects
• TIDE Project - Information Model for Machine Shop
  
• Top Level of Machine Shop Data
• PDG Core Manufacturing Simulation Data
• Simulation Standards Consortium

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Manufacturing Simulation Applications

• Manufacturing system design and engineering
• Resource estimation
• Plant layout and visualization
• Manufacturability analysis
• Process planning
• Process validation
• Ergonomic task evaluation

• Supply chain management
• Scheduling
• Capacity analysis
• Sensitivity analysis
• Cost modeling estimation
• Training Education
• User interface design

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Simulation Problem Summary

• Simulation technology holds tremendous promise
  for
• reducing the cost of manufactured products,
• improving products quality, and
• shortening products time-to-market.
• Unfortunately, simulation technology remains
  largely underutilized by industry today.
• Factors inhibit the development of simulation
• custom simulator development is complex and
  costly,
• custom translators are needed to run commercial
  simulation software.
• New simulation interface standards could help
  address this problem.

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Simulation Standards Opportunities

• Interface standards could
• reduce expenses of simulation acquisition and
  deployment,
• minimize model development time and costs,
• simplify data import and export, and
• provide new functionality that is not available
  today.
• Simulation technology and standards have been
  repeatedly identified by American industry as a
  top research priority that promises high
  payback.
• Source National Research Council Reports

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Government (NIST) Roles in Standards

• Promote use of MS technology in manufacturing
  industry
• NIST represents the U.S. in the international and
  domestic standards community (ISO, IMS, IEEE)
• Work with government agencies, end users,
  simulation vendors, and research institutions to
  identify, define and develop standards
• Adopt and recommend commercial standards for se
  by MS community
• Organized and managed Simulation Standards
  Consortium
• Organized and managed PDG Core Manufacturing
  Simulation Data

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• Navy Manufacturing Technology Program
• Manufacturing Engineering Tool Kit

Develop interfaces and demonstrate integration of
engineering tools with manufacturing shop floor
and machine tool simulators to validate
manufacturing plans, programs, and data
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Intelligent Manufacturing Systems
Program MISSION Modeling and Simulation
Environments for Design, Planning, and Operation
of Globally Distributed Enterprises

• Develop interfaces and mechanisms for integrating
  COTS manufacturing simulation software to meet
  the needs of globally distributed enterprise
  modeling in various enterprise domains

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Distributed Mfg Simulation Demonstrator
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IMS MISSION Results

• Distributed Manufacturing Systems Architecture
  Document
• Distributed Manufacturing Systems (DMS) Adapter
• Based on DoDs HLA (Author Frank Riddick)
• Documentation released
• Demonstration Distributed simulation based on
  DMS Adapter

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• Systems Integration for Manufacturing
  Applications
• Assembly Line Design

Identify simulation modeling and data interface
requirements for modeling manual manufacturing
assembly lines
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• Systems Integration for Manufacturing
  Applications
• Production System Engineering

Develop activity models and data interfaces for
the design, engineering, and simulation of
manufacturing systems
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• Systems Integration for Manufacturing
  Applications
• Skilled Factory Worker Simulation

Develop interfaces to simulate skilled factory
worker behaviors based upon hierarchical finite
state machines and human figure animation
capabilities
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Systems Integration for Manufacturing
ApplicationsTime Consuming Model Development
Issue
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• Manufacturing Simulation and Visualization
  Program
• 3D Scanning Capability

Establish a capability that will allow
researchers to rapidly construct 3D models of
complex objects to support the development of
virtual reality-based manufacturing simulations
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• SEI Technology Insertion, Demonstration and
  Evaluation (TIDE) Program
• Generic Machine Shop Simulator

Develop a generic machine shop simulation model
and neutral interfaces for integration with
scheduling, manufacturing execution system, and
other applications in job shop environment
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Our TIDE Project Partners

• Wright Patterson Air Force Base (Funding Source)
• Doyle Center for Manufacturing Technology
• National Institute of Standards and Technology
  (NIST)
• Carnegie-Mellon University - Robotics Institute
• Duquesne University
• Kurt J. Lesker Company (KJLC)

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Shop Data Types

• Organizations
• customers suppliers
• departments
• Product process specifications
• parts
• bill of materials
• process plans routing operation sheets,
  machine programs
• Production operations
• calendars shifts
• work orders, jobs, tasks
• schedules
• procurements
• Inventory
• Layout

• Resource definitions
• stations
• machines setups
• cranes
• tools fixtures
• employees
• Setup Definitions
• Skill Definitions
• Operation Definitions
• Maintenance Definitions
• Miscellaneous
• revisions
• references
• units of measurement
• probability distributions

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TIDE I Project Results

• Machine shop data specifications
• A data editor that implement the machine shop
  data specifications
• Future plans to include other data structures
  such as supply chain, aerospace assembly
  operations, automotive vehicle assembly
  operations, plant layout data (SDX), and other
  elevant manufacturing and simulation information.
• TIDE II project generic distributed supply chain
  simulation
• Demonstration Supply chain simulation

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Simulation Standards Consortium

• NIST-led Consortium to address industry
  manufacturing simulation standards needs
• Work with simulation user and vendor community to
  promote simulation technology and standards
  opportunities
• Identify and prioritize industry interface
  standards requirements
• Harmonize and integrate relevant existing and
  evolving specifications and standards
• Work with vendor to implement solutions
• Develop new draft standards specifications and
  prototype implementations that demonstrate
  feasibility
• Initiated in 2003
• Consortium Manager Swee Leong, [phone]

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Simulation Standards Consortium

• Government
• Defense Modeling Simulation Office
• Naval Educational Training Command
• NIST (Coordinator)
• Wright Paterson Air Force Base
• Software Vendors
• Brooks Automation - Autosimulation
• Delmia
• EDS / UGS
• Flexsim
• Knowledge Based Systems Inc.
• MicroAnalysis and Design
• ProModel Corporation
• Proplanner
• Rockwell Software Systems Modeling
• Simul8
• Softimage
• Wolverine Software

• Industry
• Boeing
• Ford Motor Company
• Forging Industry Association
• General Motors
• John Deere
• Kurt J. Lesker Company
• Makino Machine Tool
• Research Institutions
• Software Engineering Institute
• Academia
• Florida International University
• Carnegie Mellon University
• Virginia Polytechnic Institute
• University of Arizona
• University of Cincinnati

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SISO SIW PDG Core Manufacturing Simulation
Data

• This Product Development Group (PDG) defines a
  data interface specification for efficient
  exchange of manufacturing life cycle data in a
  simulation environment. The specification
  provides neutral data interfaces for integrating
  manufacturing software applications with
  simulation systems. The initial effort is
  focusing on machine shop definitions. The plan is
  to extend the data specification to include
  supply chain, aerospace assembly operations,
  automotive vehicle assembly operations, plant
  layout data (SDX), and other relevant
  manufacturing and simulation information.
• Prototype implementations
• Kurt J. Lesker (TIDE) Implementing machine shop
  data specification with manufacturing execution
  systems(MES) and scheduling systems
• The Boeing Company, Delmia and NIST joint project
• wing assembly lines
• Early discussion with a major automotive
  manufacturer
• TIDE II generic distributed supply chain
  simulation
• PDG Kick-off Meeting
• Tuesday September 20, 2004 from 1330 to 1430
• Location Dolphin

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Final Demo A simulation with multiple
perspectives

• Man-machine-materials interactions
• Human factor and operator safety perspective
• Work cell and plant layout perspective
• Engineering perspectives
• Integrated engineering to manufacturing
  perspectives

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Other Speakers

• Emmanuel (Em) delaHostria Rockwell Automation
• Bob Brown Delmia Corporation
• Richard Zarda Lockheed Martin
• Dave Koshiba - Boeing

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Questions and discussion