hmis direct the manufacturing processiom.invensys.com/en/softwaregcc14presentations/general...
TRANSCRIPT
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ATK is a registered
trademark of
Alliant Techsystems Inc.
Chris Anderson – ATK
Sr. Manufacturing Analyst
Bill Baker – ATK
Sr. Software Engineer
October 1, 2014
HMIs Direct the
Manufacturing
Process
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Agenda
• About ATK
• Discuss the evolution of HMIs
• Concept Stage
• Prototype Stage
• Release Stage
• Continuous Improvement
• Tangible Benefits
• Reduced (Eliminate) Errors
• Reduced Process Time
• Review Really Cool HMIs
• Process Flow
• System Interfaces
• HMIs
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Sub-Contractor
38% Prime Contractor
62%
Sales by Contract Type
• Headquartered in Arlington, VA, with approximately
16,000 employees
• $4.8B in sales and $5.8B orders
• Company/customer funded R&D $750M
• More than 60 facilities in 22 states, Puerto Rico and
Internationally
• Representatives in more than 50 countries throughout
the world
• Last 18 months: acquired Savage Arms and Bushnell
Commercial/ International
47%
U.S. Army 20%
NASA 9%
U.S Navy 10%
U.S. Air Force 4%
Other U.S. Government
10%
Sales by Customer
ATK at a Glance- They Made Me Do it
Aerospace Group Defense Group Sporting Group
Results are for the fiscal year ended March 31, 2014
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About ATK – Our Place
Aircraft Commercial Center of Excellence (ACCE)
Located in Clearfield, Utah
Anchor Programs: Airbus A350 / A400M and Roll-
Royce
• Floor Space: 615,000 sq ft
• 100,000 sq ft Clean Room Capacity
• 15,000 sq ft Office Space
• 2,500 sq ft Freezer Capacity
• Automated Stiffener Forming Capacity
• Automated Linear Stringer Machines
• Automated Radial Frame Machines
• Engine Case Wrap Capacity
• CNC Milling Machine Capacity
• Large Diameter Autoclave Capacity
• NDI Systems - Automated Ultrasonic Inspection
(AUIS)
• Water Jet and Machining Capacity
• Hot Drape Forming
MANUFACTURING AREA
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About ATK – Our Place
MANUFACTURING AREA Freeport Composite Center
Located in Clearfield, Utah
Anchor Programs: Boeing 787 and
Lockheed Martin F-35
• Floor Space: 403,000 sq ft
• Clean Rooms
• Fiber Placement Machines
• Case Wrappers
• Ovens
• CNC Milling Machines
• Lathes
• Autoclaves
• Automated Ultrasonic Inspection
Systems (AUIS)
• ASFM Machines
• Pattern Cutter
• Leica Measurement Systems
• Laser/Radar Measurement Systems
• Virtek Projection Systems
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In the Beginning…
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Concept Stage - Shop Floor and MFG Systems
Solumina Shop Floor PC
Barcode Scanner
Engineering Desk PC
Oracle 10g
Solumina / Impresa
Data
Oracle 10g
ePIC Data
EWI &
MRP
PLM
1. Keep current MES’ish
Systems
Goals
Shop Floor Machine
Control PC
2. Talk to Shop Floor
machines
3. No sneaker-net
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Concept Stage - PLM , EWI, Control PC
Engineering Desk PC
Part Program - Name - Revision - Location
ePIC Solumina
Work Order - Part Program - Name - Revision
Control PC
Machine Designation Part Programs Output Data Files Output Reports
700+ Part
Numbers
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Prototype Stage
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Prototype Stage – Take One
Shop Floor Machine
Control PC
Solumina Shop Floor
PC
Barcode Scanner
Oracle 10g
Solumina / Impresa
Data
Engineering Desk PC
Part Files
MS Win MFG File Server
ATK network MFG subnet
Oracle 10g
ePIC Data
• Machine controls say
take a hike
• Use EWI for interface
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Prototype Stage – Take Two
Shop Floor Machine
Control PC
Solumina Shop Floor
PC
Barcode Scanner
Oracle 10g
Solumina / Impresa
Data
Engineering Desk PC
Part Files
MS Win MFG File Server
ATK network MFG subnet
Oracle 10g
ePIC Data
• Bug machine
controls until they
give in
MS SQL Express
Machine Specific
Data
• Use Local DB for
interface
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Prototype Stage – Let’s Go into Production
Solumina / Impresa
Data
Engineering Desk PC
Machine G
Machine Specific
Data
Machine C
Machine Specific
Data
Machine B
Machine Specific
Data
Machine E
Machine Specific
Data
Machine F
Machine Specific
Data
Machine D
Machine Specific
Data
Machine A
Machine Specific
Data
Take Three
• IT states we’re nuts
• Starting to panic
• Go with it anyhow
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Release Stage
“Release the Kraken”
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Release Stage – First Big Tweak
Shop Floor Machine
Control PC
Solumina Shop Floor
PC
Barcode Scanner
Oracle 11g
Solumina / Impresa
Data
Engineering Desk PC
Part Files
MS Win MFG File Server
ATK network MFG subnet
Oracle 11g
ePIC Data
MS SQL Server
Machine Data
• Single SQL Server for
multiple machines
• Process Specific HMIs
- UI/Interface Wrapper - SQL Calls
HMI
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Release Stage - HMIs
Tool Prep HMI
Vacuum Bag
HMI
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Release Stage - HMIs
Vacuum Timer
Open WO
Material Usage
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Continuous Improvement
There was an engineer, manager and programmer driving down a steep mountain
road.
The brakes failed and the car careened down the road out of control.
Half way down the driver managed to stop the car by running it against the
embankment barely avoiding going over a cliff.
They all got out, shaken by their narrow escape from death, but otherwise
unharmed.
The manager said "To fix this problem we need to organize a committee, have
meetings, and through a process of continuous improvement, develop a solution."
The programmer said "I think you're both wrong! I think we should all push the car
back up the hill and see if it happens again."
The engineer said "No that would take too long, and besides that method never
worked before. I have my trusty pen knife here and will take apart the brake system,
isolate the problem and correct it."
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Continuous Improvement – Cool Integration
Solumina / Impresa
Data Oracle 10g
Engineering Desk PC
Part Files
MS Win MFG File Server
Shop Floor
Machine
Web Services
Web Server
Control PC
Oracle 10g
ePIC Data
MS SQL Server
InfinityQS (SPC) Data
- UI/Interface Wrapper - Web Services
HMI
MS SQL Server
Machine Data
Barcode or RFID Scanner
Manual Station
or
OAT RFID Data
SQL Server
• Add one heaping
batch of Web
Services
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Continuous Improvement – Sustainable HMIs
Control PC
- UI/Interface Wrapper
HMI
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Continuous Improvement – Off the Shelf
ArchestrA System Platform
ePicSolumina
Visual
Action BoardInfinityQSEMS
TC Mapping
SOA Platform (Apache Tomcat, Microsoft IIS Webservers)
MPM-01
HMI
CART LOAD
HMI
CART
UNLOAD
HMI
DIM-03
HMI
COV-01
HMI
AUIS-7
HMI
MC-11
HMI
CAC-01
HMI
ASFM-L04
HMI
ASFM-R02
HMI
TOOL PREP
HMI
BAG
HMI
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Continuous Improvement – OMP
ArchestrA System Platform
ePicSoluminaVisual
Action BoardInfinityQSEMSTC Mapping
OMP Manufacturing Information Bus
MPM-01
HMI
CART LOAD
HMI
CART
UNLOAD
HMI
DIM-03
HMI
COV-01
HMI
AUIS-7
HMI
MC-11
HMI
CAC-01
HMI
ASFM-L04
HMI
ASFM-R02
HMI
TOOL PREP
HMI
BAG
HMI
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Now for the good stuff…
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Tangible Benefits – Failures w/o HMI
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Tangible Benefits – Failures w/ HMI
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Tangible Benefits – Failures Detail
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Tangible Benefits – Cycle Time Improvements
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Tangible Benefits – Cycle Time Details
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HMI Review
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HMIs – Process Flow
1- Tools Arrive
Start Tool Prep
Process
Conveyors
3- Vacuum Bagging
Process
2- Part
Forming
Machine
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HMIs – System Interfaces
HMI
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Tool Prep HMI - Start Operation
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Tool Prep HMI – Scan Tool to Retrieve WO
Applicable
work orders
Scanned tool
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Tool Prep HMI – Perform Work
Material
location on tool
Required
Materials
Required Software
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Tool Prep HMI – Material Usage
Consumed
Materials
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Vacuum Bag HMI - Start Operation
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Vacuum Bag HMI – Scan Tool
Scanned tool
Applicable work
orders
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Vacuum Bag HMI – Open WO & Perform Work
Graphical
Representation
of part
Required Caul Software Detail
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Vacuum Bag HMI – Scan Cauls
Cauls
Scanned
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Vacuum Bag HMI – Vacuum Test Timer
Vacuum Timer
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Vacuum Bag HMI – Complete Operations
All Operations
Completed
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Q & A
Please be gentle