Introduction
IPC Digital Manufacturing Platform
For Industry 4.0
Edward Acheson, IPC-2581 Consortium Chair, Sr. Principle Product Engineer at Cadence Design Systems, Inc.
Major Contributors: Michael Ford, Aegis Software, Hemant Shah Cadence Design Systems
1. What is Industry 4.0?
2. IPC CFX IIoT Communication
3. The IPC-1782 Digital Build Record
4. The IPC-2581 Digital Product Model
5. IPC Industry 4.0 Digital Manufacturing
DesignSolution
EngineeringSolution
MESSolution
TraceabilitySolution
DFMSolution
Legacy Design Through Manufacturing
The Legacy Manufacturing Engine• Inconsistent data without provenance or value• Needless delays, costs and lost opportunity• Mistakes affecting quality & reliability• Impossible to support Industry 4.0
DigitalDesign
Solution
DigitalEngineering
Solution
DigitalMES
Solution
DigitalTraceability
Solution
DigitalDFM
Solution
IPC Digital Manufacturing Engine
Digital Engine Components:• IPC standards form digital best practices• Design - Manufacturing - Design• Enables inter-operable solutions• Comprehensive, sustainable Industry 4.0
People making decisions, take time:• Discovery / discussion / uncertainty• Delays impact business flexibility
Decisions Will Be Enhanced By Digitalization:• Visibility of every aspect of the operation• Decision support including value and consequence
Decisions Will Be Made By Digitalization:• Increasing use of “AI” to make decision• Simple at first, will grow in complexity
Industry 4.0: Automation of Automation
Is your data good enough to trust?
Business Case:• Manufacture close to the market• Minimize distribution chain costs (logistics, depreciation)• Protection against taxes and tariffs
Business Challenges:• How to “Build to Order” with “Mass Production
Efficiency”?• How to make many disparate systems work together?• What to do with humans in the digital factory?
Industry 4.0 Is About Business
What Is Connected Factory Exchange (CFX)?
Triggered By 30 Years of Frustration:• Difficulties to acquire live accurate manufacturing data• The need for actionable data for Industry 4.0
The IPC CFX Standard: • Hundreds of vendors & solution providers working together• Genuine IIoT “plug & play” standard for Industry 4.0• Eliminate waste & enable digital value creation• Available free to companies of all sizes in all sectors• Working with IPC-2581 digital product & process modelling
CFX Components For True Plug And Play
Communication Protocol
Defined Language Content
Data is Encodedusing• Secure (like ATM)
• Encrypted option• Send and forget (host)• Point to point (direct)
• Structured topics and messages across all manufacturing elements
• “Build” a model for any type of automation
Driving CFX Adoption
Publication expected September / October 2018
• Open-source SDK available free of charge from IPC• No fees, licenses, bespoke hardware or middleware• Almost 50 native machines trials already implemented• “Drop-in” SDK supports bespoke machines & systems• Very old unsupported machines require conversion
Traceability Business Case:• Reduce cost of manufacturing issues• Reduce scope of re-work• Supports “do it right the first time”• Find unique reasons behind defects• Immediate shipping confidence• Anti-counterfeit tool• The use of CFX makes traceability “free” to manufacturing
Insurance•
Assurance QualityDigital Product Model Values
Digital Build Record: IPC-1782 Traceability
Digital Components of Traceability:
• Product model (design)• Process model (configuration/programs)• Materials and tools etc. used & source information• Process flow events & faults, operator actions• Test and inspection measurements• Potential to benchmark performance of design features
Contents Of IPC-1782
IPC-2581: Intelligent Design DataDigital Best Practice Design To Manufacturing
IPC-2581 Digital Product Model:• The complete digital PCB product model• As simple as a single file• Design and local BOM data & variants• Ready for direct process engineering tasks
Legacy “Design Through Manufacturing” Flow
Experience:• Hands-on• Inconsistent• Incomplete• Erroneous• Many emails!
Consequences:• A lot of work• Excessive lead-time• Inevitable mistakes
Experience:• Single click• Reliable• Dependable• Accurate
Consequence:• Almost zero work• Very short lead-time• No mistakes
Digital Best Practice Design Through Manufacturing
Digital Design (since 1980s):• So, why not Digital Engineering?
Traditional Model:• Digital-ish, manual, days• Time for one configuration
IPC-2581 Digital Flow:• Digital end to end flow, minutes• Single digital product model, re-used• Time for many configuration options• Critical to Industry 4.0
IPC-2581 Digital Flow Velocity
DigitalEngineering
DigitalDesign
Happening TODAY With IPC-CFXEnabling Industry 4.0
IntelligentHand-off
Adoption of IPC-2581 Is Becoming Dominant
Case Study:• 2018 target over 60% jobs• Typical example from:
Conclusion:• Digital engineering support for
Industry 4.0 is ready to go!% Of Manufacturing Jobs Using IPC-2581
IPC-2581 Consortium: 98 Corporate Members
OEMs:Cisco, EMC, Ericsson, MSFT, FLIR, Fujitsu Network Communication, Huawei, Harris, LMCO, QCOM, Qlogic, NVIDIA, Orbital, ZTE
ECAD:Altium, Cadence, Zuken, SiSoft, Mentor Graphics, Ansoft, Intercept …
DFM/CAM Software Companies:Frontline, AEGIS, Downstream, ADIVA, Wise, Numerical, Polywog, Quadcept, Vayo….
MCAD/PLM Companies:PTC, ARAS, Siemens
EMS/FAB Companies:Axiom, Sanmina, TTM Technologies, Multek, Sierra Circuits, …
Support Enhanced DFX:• “Closing the loop” with data accumulation• Augment IPC-2581 with engineering, quality, materials, production attributes• IPC-2581 enhanced by CFX and IPC-1782
IPC-2581 Digital DFX Manufacturing
QualityFlows Quality & Yield
AnalysisQuality & Yield
Analysis
EngineeringAnalysis
EngineeringAnalysis
FeatureAttributes
ProcessAttributes
From Design
ManufacturingFlows
Back To Design
EngineeringFlows
MaterialAttributes
AugmentAugment
Enterprise Business SystemsERP / MRP / PLM
EnterpriseAttributes
Manufacturing SystemsNPI / MES / MOM
Configurable
MechanicalAttributes
ECAD & MCAD ECAD & MCAD
IPC Digital Best Practices
Engine Components:• IPC standards: A complete digital flow• Design - Manufacturing - Design• Enables inter-operable solutions• Comprehensive, sustainable Industry 4.0
QualityBest Practice
Digital Product Model
ManufacturingBest Practice
EngineeringBest Practice
Digital Process Model
Digital Thread
Complete Digital Twin
Satisfaction of business goals:• Flexible factory, automation of automation• Increased Industry 4.0 accessibility• Solution inter-operability, without waste• Human opportunities within the digital factory• Clear actionable data, from design to design
The Future of Digital Manufacturing