l6 cadlab 1112 process modeling - kaemart.it filekaemart umbertocugini topics 2 process functional...

Knowledge Aided

Engineering Manufacturing

and Related

Technologies

Lab Cad 2011/12 L6 Process Modeling

KAEMaRT UmbertoCugini

2 Topics

Process functional modeling •  Why it is necessary to model all the processes

  Design   Production planning   Manufacturing

•  Methods and tools   IDEF0 graphic language   IDEF0 Techniques and operational procedures   Example   Suggestions


3 Design CAx environment

METHOD

Process

Product & Process conception

Product & Process development

Styling Prototype building

Tooling Design

Tooling Manufacturing

Preserie Salita prod.

Try-out


4 CAx system efficiency

Efficiency derives from method and process change, not just changing tools

Steps to improve efficiency •  Document the current process (AS IS) •  Identify issues •  Understand how new technology can help •  Change the process (TO BE)


5 Process, System

A process is a set of activities concurring to achieve an objective   e.g. object production process, service rendering

process, etc.

A system is a set of strictly related elements for the accomplishment of a purpose or target   e.g. a mechanical system, a control system, etc.


6 Functional model of a process / system

Identifies and represents the activities/functions developed (what) and their logic relationships (input / output) and/or execution relationships (priority, simultaneity, synchronization, etc.)

… the final result is a model, as such indivisible from the objectives for which it was developed

and from the author’s perspective


7 Modeling techniques

•  Functional flow chart •  Pert and Gantt •  Petri Net •  IDEF0 •  IDEF2 •  IDEF3


8 Functional flow chart

Chi Che cosa Who What

Actor 1

Actor 2

Actor 3

Actor 4

Actor 5

Start Stop

P1

Q1

P3

P5 Q2

P4

P2 P6 Stop

Stop

Y N

Y

N


Pert and Gantt

PERT : Program Evaluation and Review Technique

9

P1

P2

P3

P4 P5

P6

t

Act2

Act3

P1

P2

P3

P4

P5

P6

Act1


GANTT example 10


GANTT example ID Task Name Duration Start Finish

1

2

3

4 OptiTrack 31 days? Wed 07/01/09 Wed 18/02/09

5 budget request 4 days? Wed 07/01/09 Mon 12/01/09

6 offerta disponibile 1 day? Tue 13/01/09 Tue 13/01/09

7 purchase order 1 day? Wed 14/01/09 Wed 14/01/09

8 shipment 20 days Tue 20/01/09 Mon 16/02/09

9 availability and installation 2 days Tue 17/02/09 Wed 18/02/09

10 OptiTrack configuration 3 days? Thu 19/02/09 Mon 23/02/09

11 physical setup 3 days? Thu 19/02/09 Mon 23/02/09

12 software setup 3 days? Thu 19/02/09 Mon 23/02/09

13 resolve shutter glasses and tracking system conflict 3 days? Thu 19/02/09 Mon 23/02/09

14 Hands tracking 10 days? Tue 24/02/09 Mon 09/03/09

15 physical setup 1 day? Tue 24/02/09 Tue 24/02/09

16 software setup 1 day? Mon 09/03/09 Mon 09/03/09

17 Software upgrade 31 days Mon 12/01/09 Mon 23/02/09

18 Specifications of user interaction for modification task 7 days Mon 12/01/09 Tue 20/01/09

19 New global state machine 10 days Wed 21/01/09 Tue 03/02/09

20 Specifications of new messages 7 days Wed 04/02/09 Thu 12/02/09

21 New version of Haptic Module 7 days Fri 13/02/09 Mon 23/02/09

22 Haptic 51 days? Wed 07/01/09 Wed 18/03/09

23 Strip with two servos for pitch 3 days? Wed 07/01/09 Fri 09/01/09

24 Strip with new allocation for touch sensor 4 days? Wed 07/01/09 Mon 12/01/09

25 Design and setup of admittance control 3 days Fri 13/02/09 Tue 17/02/09

26 Implementation of admittance control 7 days Thu 26/02/09 Fri 06/03/09

27 Validation of inverse kinematics with tracking system 2 days Tue 24/02/09 Wed 25/02/09

28 Components for torsion 16 days? Wed 07/01/09 Wed 28/01/09

29 Version with conic gearing 1 day? Wed 18/03/09 Wed 18/03/09

30 Buy cog rack 1 day? Wed 18/03/09 Wed 18/03/09

31 Assemble components 1 day? Wed 18/03/09 Wed 18/03/09

32 Computations for weight compensation with new configuration 1 day? Wed 18/03/09 Wed 18/03/09

33 New haptic control 1 day? Wed 18/03/09 Wed 18/03/09

34 Computations for inverse kinematics 1 day? Wed 18/03/09 Wed 18/03/09

35 Design of sensorized extremities 1 day? Mon 02/02/09 Mon 02/02/09

36 Define alternatives 1 day? Mon 02/02/09 Mon 02/02/09

37 Comparative evaluation 1 day? Mon 02/02/09 Mon 02/02/09

38 Simulation of subset of possible candidates 1 day? Mon 02/02/09 Mon 02/02/09

39 Choice 1 day? Mon 02/02/09 Mon 02/02/09

40 Prototyping 1 day? Mon 02/02/09 Mon 02/02/09

41 Testing 1 day? Mon 02/02/09 Mon 02/02/09

42 Bruno @ PoliMi 5 days? Mon 02/03/09 Fri 06/03/09

43 User test 7 days Fri 06/03/09 Tue 17/03/09

44 Software available 0 days Fri 06/03/09 Fri 06/03/09

45 Test session 2 days Mon 09/03/09 Tue 10/03/09

46 Test results 5 days Wed 11/03/09 Tue 17/03/09

47

48 Deliverable 8.2 52 days? Mon 12/01/09 Tue 24/03/09

49 Specifications of global modification (tasks for the early test) 5 days? Mon 12/01/09 Fri 16/01/09

50 Full specifications for modification task 30 days Mon 19/01/09 Fri 27/02/09

51 Draft deliverable 8.2 5 days Mon 02/03/09 Fri 06/03/09

52 Deliver 8.2 5 days Wed 18/03/09 Tue 24/03/09

Francesco

Francesco

Mario

Bruno

Mario

Mario

Bruno

Bruno

Michele, Bruno

Michele, Bruno

Michele

Mario

Mario

Michele

Michele

Michele

Mario

Bruno, Michele

06/03

Unott

Michele

S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W04 Jan '09 11 Jan '09 18 Jan '09 25 Jan '09 01 Feb '09 08 Feb '09 15 Feb '09 22 Feb '09 01 Mar '09 08 Mar '09 15 Mar '09 22 Mar '0

Task

Split

Progress

Milestone

Summary

Project Summary

External Tasks

External Milestone

Deadline

Page 1

Project: MSProj11Date: Fri 30/01/09

11


12 Petri Net

p2p1

p3

t1

p4 p5

t2

p6

t4

p8

p9

t5

t3

p7


13 IDEF0

A0

P. 2

D1 D2

O3

O4

O6

O1

O2

P1

A1

P2

A2

P3

A3

P4

A4

O5

D3

O1

O2

D1 D2

O3

O4

O6


14 IDEF0 modeling of a process / system

An IDEF0 model identifies and represents : •  Activities/functions executed (what it does) •  Constraints to the execution of such activities/functions

(what controls it) •  Input data/objects (what it processes) •  Resources (what it uses) •  Output data/objects (what it produces)


15 An IDEF0 model of a production process

Identifies and represents : •  activities/functions executed

  definition of product specifications, design, production, etc.

•  constraints to the execution of activities/functions   market analysis, user-target characteristics, company history,

project standards, machine technical characteristics, etc.

•  input objects/data   ideas, raw materials, etc.

•  resources   People, HW/SW resources, plants, space, etc.

•  output objects/data   product specifications, drawings, parts list, semi-finished, finished

product, etc.


16 An IDEF0 model of a mechanical system

Identifies and represents : •  activities/functions executed

  the transformation of energy, the application of forces, etc.

•  constraints to the execution of activities/functions   resistance, wear, etc.

•  input objects/data   energy, work, etc.

•  resources   mechanical parts, etc.

•  output objects/data   energy, work, etc.


17 IDEF modeling family

Includes:   IDEF0 Function model   IDEF1/IDEF1X Information model   IDEF2 Dynamics model   IDEF3 Process flow description

IDEF0 includes   IDEF0 graphic language for functional modeling of a process or

system   IDEF0 techniques and working procedures ensure consistent and

rigorous use of the language

IDEF0 can support   the analysis of present processes /systems (AS IS)

  the design of new processes /systems (TO BE)


IDEF history

•  IDEF0 is based on SADTTM (Structured Analysis and Design Technique TM), developed in 1972 by Douglas T Ross at SofTech Inc.

•  Was chosen by DoD as basis for documentation of USA Defense supplies.

•  From 1994, IDEF0 is an FIPS standard(Federal Information Processing Standards) Publication 183 in the public domain.

•  Available at : www.idef.com/Downloads/free_downloads.html

18


s/w tools for IDEF modeling & simulation

•  Design/IDEF di Meta Software Corp. •  (http://www.metasoftware.com/home.html/)

•  AI0 Win di Knowledge Based Systems, Inc. (KBSI) •  (http://www.kbsi.com/)

•  SystemArchitect/BPR di Popkin Software Systems, Inc. •  (http://www.popkin.com/)

•  Simprocess •  (http://www.caciasl.com/)

…..


20

Activityname

Activitycode

Mechanism

Control

Input Output

Graphic Language: Box and arrows

Box   Activities/functions

Arrows   Data/objects

•  Input •  Controls •  Output •  Mechanisms


21 Graphic Models and Diagrams

A-0

0A0

A0

1

2

3

4A4

( )

( )

I1

C1

M1

O1A4

A4

1

2

3

I1

M1

O1

•  Diagrams   Detailed graphic description of activities/functions

•  Graphic Model   Graphic description of process/system

A0

1

2

3

4A4


22 IDEF0 Model

A0

1 2

3 4 A4

Glossary Explanation

Modello grafico


23 IDEF0 techniques and operating procedures

Support: •  Development of the model of a process / system:

  Information acquisition   Model editing, consolidation and validation   Model documentation

•  Model reading and interpretation


24 Some suggestions

•  Identify the objective of the model and the developing criteria (standpoint), then proceed consistently in modeling

•  “… constrain, don’t sequence ..” as the model shows the constraints, not the sequence

•  Pay attention to the development of the graphic layout as this makes the document easier to read and validate

•  Extensively add information in the model (notes, texts, glossary, …)

•  Models should not be too large and complicated


An example… context diagram

Preparareuna cena

per degli amiciA0

P. 2

Numeroospiti

Ricettario

$

Isabella

Cena

Supermercato

Purpose: pianificare la preparazione di una cena per degli amiciViewpoint: Isabella, l'ideatrice e la risorsa principale del processo


An example … A0 diagram Numero

ospitiRicettario

Cena

$

Selezionareil menu'

A1

P. 3

Acquistaregli ingredienti

A2

Cucinare

A3

Prepararela tavola

A4

Menu'

Ingredienti

Piatticucinati

Tavolapreparata

Isabella Supermercato


An example… A1 diagram Ricettario

Menu'

Isabella

Selezionarel'antipasto

A11

Selezionareil primo piatto

A12

Selezionareil secondo

piattoA13

Selezionareil dolce

A14

Selezionarei vini

A15

Antipastoselezionato

Primo piattoselezionato

Secondo piattoselezionato

Viniselezionati

Dolceselezionato


An example…activities connections(Pert)

Selezionareil menu'

A1


A2Cucinar e

A3

Pr epararela tav ola

A4


An example … resources and durations Numero

ospitiRicettario

Cena

$

Selezionareil menu'

A10.5h

P. 3


A21.0h

Cucinare

A33.0h

Prepararela tavola

A40.5h

Menu'

Ingredienti

Piatticucinati

Tavolapreparata

Isabella Supermercato


An example … resources and durations Numero

ospitiRicettario

Cena

$

Selezionareil menu'

A10.5h


A21.0h

Cucinare

A33.0h

Prepararela tavola

A40.5h

Menu'

Ingredienti

Piatticucinati

Tavolapreparata

Isabella SupermercatoAnna


Soluzioni ottimali rispetto alla durata complessiva del processo:

Sel ezi onarei l menu'

A1

A cqui staregl i i ngredi enti

A2C ucin are

A3

Prepararel a t avol a

A4

12

3

2A1

A2A3

A4

0 t0.5 4.51 1.5

Un esempio ... pianificazione temporale (Gantt)


Example 32

Company (human resources, infrastructure,

HW/SW tools, machines, tooling, etc.)

Product Product

Certification

Raw Materials, Semi-finished,

Buy components

Company Historical Data

Company Know-How (competence, standards, etc.)

Design/Production of a mechanical system (vehicle, aircraft, etc.)

A0

P. 2

Node A-0 Context Diagram


Example 33

Node A0 Design/Production ...

Design

Definition of specifications

Concept

Process Design

Product certification

Manufacturing & Assembly


34

Node A0 Progettazione/Produzione ...

Progettazione

Definizione specifiche

A1

Studio

Progettazione processi

Certificazione prodotto

A5

Fabbricazione e assembl.

A6

Specifiche

Strategie aziendali

Tipologia prodotto


35


Progettazione

A3


A1

Studio

A2


A4


A5


A6

Specifiche tecniche

Specifiche

Strategie aziendali

Tipologia prodotto


36


Progettazione

A3


A1

Studio

A2


A4


A5


A6

Richieste di revisione

Specifiche tecniche

Progetto assieme e componenti

Specifiche

Strategie aziendali

Tipologia prodotto


37


Progettazione

A3


A1

Studio

A2


A4


A5


A6


Specifiche tecniche



Progetto processi di produzione e assembl.

Specifiche

Strategie aziendali

Tipologia prodotto


38


Progettazione

A3


A1

Studio

A2


A4


A5


A6


Specifiche tecniche





Specifiche

Strategie aziendali

Tipologia prodotto Normative (ISO-9000, ecc.)


39


Design

A3


A1

Study

A2

Process Design

A4

Product Certification

A5

Manufacture & Assembly

A6

Review Request

Technical Specifications

Design of assembly and components

Review Request

Product


Design of production and assembly process

Specs

Raw materials, Semi-finished,

Buy components

Company Input

Type of product Standards (ISO-9000, etc.)


40


Design

A3


A1

Concept A2

Process Design

A4


A5

Manufacture & Assembly

A6

Review Request

Technical Specifications

Design of assembly and components

Review Request

Product


Design of production and assembly process

Specs

Raw materials, Semi-finished,

Buy components

Company Input

Type of product Standards (ISO-9000, etc.)


41


Progettazione

A3


A1

Studio

A2


A4


A5


A6


Specifiche tecniche



Prodotto



Specifiche

Materie prime, semilavorati,

componenti buy

Strategie aziendali



42

Progettazione

A3


A1

Studio

A2


A4


A5


A6


Specifiche tecniche



Prodotto



Specifiche

Materie prime, semilavorati,

componenti buy

Strategie aziendali




43

Node A3 Design

Set-up of assemblies

A31

Component Design

A32

Analysis of assemblies (FEA, etc.) A33

Prototyping of assemblies

A34

Relation between components, macro-shape and location constraints

Review Request

Assembly Design Component

Design

Review Request

Testing of assemblies

A35

Component Prototype

Assembly Prototype


44

Node A3 Design

Set-up of assemblies

A31

Component Design

A32

Analysis of assemblies (FEA, etc.) A33

Prototyping of assemblies

A34

Relation between components, macro-shape and location constraints

Review Request

Assembly Design Component

Design

Review Request

Testing of assemblies

A35

Component Prototype

Assembly Prototype


45

Node A3 Progettazione

Impostazione assieme

A31

Progettazione componenti

A32

Analisi assieme (FEA, ecc.)

A33

Prototipazione assieme

A34

Relazioni tra componenti, macro-forma e vincoli di posizionam.


Progetto assieme Progetto

componenti


Verifica assieme

A35

Prototipi componenti

Prototipi assieme


46

Impostazione assieme

A31

Progettazione componenti

A32

Analisi assieme (FEA, ecc.)

A33

Prototipazione assieme

A34

Relazioni tra componenti, macro-forma e vincoli di posizionam.


Progetto assieme Progetto

componenti


Verifica assieme

A35

Prototipi componenti

Prototipi assieme

Node A3 Progettazione


47

Definition of macro-shape and positioning constraints

for main components A311

Solution/Choice of interfaces

A312

Assembly pre-analysis (assemblability, kinematics,

etc.) A313

Secondary components, relationship btw. components, macro-shape and position constraints

of secondary components

Macro-shape and position constraints for main components

Review Request

Review Request

Relationship btw. components, macro-shape

and position constraints.

Node A31 Assembly Set-up


IDEF0 techniques & procedures

Tecnica IDEF0 Informazioni

(Know-How di processo, Norme aziendali, ecc.)

Acquisizione delle informazioni

A1 Redazione

del mod. IDEF0 tentativo

A2 Analisi

del modello IDEF0 A3

Revisione del modello IDEF0

A4

Analisti Esperti di processo

Modello IDEF0 consolidato e documentato

Documentaz. del modello IDEF0

A5

Modello IDEF0 tentativo

Informazioni

Modello IDEF0 con richieste di rev.

Tecnica IDEF0 per l'acquisizione delle informazioni

Tecnica IDEF0 per la revisione del modello

Tecnica IDEF0 per la lettura /interpretazione /commento del modello

Tecnica IDEF0 per la redazione del modello

Modello IDEF0 consolidato

Tecnica IDEF0 per la documentazione del modello

Modello IDEF0 rivisto


IDEF 3

IDEF3 is a modeling technique to functionally model processes focused on execution flows

IDEF3 allows to represent in addition to activities : Sincronization of activities (Junction) Constraints and extra infos (Referent)

IDEF3‑Process Flow is part of the IDEF3 Process Description Capture Method .

IDEF3 Process Description Capture Method include also IDEF3‑Object State Transition Network used to model the different product evolution states during the overall process.

IDEF3 specs are available at:

www.idef.com/Downloads/free_downloads.html


Example

Ce naOb jec t/

A44

Prepara rela tavola

A33

Cu cinare

A22

Ac qu istaregli ingre dienti

A11

Se lez io narei l m enu '

Prepara re cena

&J2

&J1

L3

L2

L5L4

L3

L2

L1


IDEF 3 Decomposition

&

&

&

3

3.1.6

3.1.7

3.1.8

3.1.9 3.1.10

3.1.11


Modelli IDEF0 AS-IS

FERRARI example


Modelli IDEF0 To-Be

FERRARI example


Modelli IDEF3-Process Flow As-Is


Modelli IDEF3-Process Flow To-Be


Simulation Simprocess Professional 2.1 (CACI Products Company)


Elaborazione dei dati campionari

Calcolo di media, varianza, distribuzione e ripartizione dei dati campionari inerenti:

  Lead time   Tempo di innesco dei cicli di revisione/ottimizzazione

progetto (*)   Numero di cicli di revisione/ottimizzazione progetto(*)   Probabilità mensile di innescare uno o più cicli di

revisione/ottimizzazione progetto (*)

(*) per i cicli interni, esterni e interni ed esterni


Lead time: q 28%

NB Le tempistiche sono state sistematicamente alterate per salvaguardare la riservatezza dei dati dell’azienda

00.10.20.30.40.5

t (months)

PASIS

A S IS 0 0 0 0 0 0 0.25 0.12 0.1 0.21 0.1 0.09 0.05 0.04 0.02 0.01 0 0 0

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

00.10.20.30.40.5

t (months)

PTOBE

T OB E 0.35 0.17 0.18 0.12 0.07 0.06 0.03 0.01 0.01 0 0 0 0 0 0 0 0 0 0

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

As-IsMedia: 24.82 mesi ±0.17Varianza: 5.27

To-BeMedia: 17.83 mesi ±0.15Varianza: 4.17


0

0.1

0.2

0.3

0.4

t (months)

PASIS

A S IS 0.04 0 0 0.03 0.01 0.02 0.07 0.05 0.05 0.36 0.15 0.09 0.1 0.03 0 0 0 0 0 0 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

0

0.1

0.2

0.3

0.4

t (months)

PTOBE

T OB E 0.03 0 0.01 0.05 0.05 0.17 0.11 0.27 0.11 0.06 0.07 0.04 0.01 0 0 0 0 0 0 0 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

As-IsMedia: 9.6 mesi ±0.23Varianza: 7.62

To-BeMedia: 7.55 mesi ±0.21Varianza: 5.76

NB Le tempistiche sono state sistematicamente alterate per salvaguardare la riservatezza dei dati dell’azienda

Tempo di innesco dei cicli: q 21%


Numero di cicli: q 2%

00.10.20.30.40.50.6

Nr

PASIS

A S IS 0.21 0.29 0.23 0.16 0.07 0.04 0.01 0

0 1 2 3 4 5 6 7

00.10.20.30.40.50.6

Nr

PTOBE

T OB E 0.25 0.25 0.23 0.15 0.08 0.03 0.01 0

0 1 2 3 4 5 6 7

As-IsMedia: 1.73 ±0.1Varianza: 1.93

To-BeMedia: 1.7 ±0.11Varianza: 2.16


Analisi dei risultati

Coerentemente con le aspettative Ferrari …   28% lead time   21% tempo di innesco dei cicli

Inoltre:   15% numero di cicli interni   26% numero di cicli esterni

… occorre considerare anche il contemporaneo aggiornamento delle tecnologie CAD aziendali


72 Summary

Process functional modeling

l6 cadlab 1112 process modeling - kaemart.it filekaemart umbertocugini topics 2 process functional...

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