Manufacturing Process
Modeling in Systems
Architectures
Gregory Pollari
Advanced Manufacturing Technology
INCOSE International Workshop 2012
Jacksonville FL
January 22, 2012
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
Acknowlegements
• At Georgia Tech
– Dr. Leon McGinnis, Eugene C. Gwaltney Chair in Manufacturing
Systems and Professor
– Dr. Ola Batarseh, Researcher
– Dr. Volkan Ustan, Researcher
• At Rockwell Collins
– Jim Lorenz, Manager Advanced Industrial Engineering
– Dan Turner, Material & Process Engineer
– Todd Boyle, Material & Process Engineer
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
2
Model Based Manufacturing Challenge
• Desire early Manufacturing involvement during system design
• Requiring systems engineers to “speak manufacturing” is a
challenge
• How can Manufacturing engage during the systems design
phase without “getting in the way?”
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
3
Today’s Manufacturing Analysis Workflow
• Two problem classes
– Analytical (mathematical relationship, or rule, can be verified)
– Visual (difficult to write a rule, but easy to see)
• Start at detailed design
–
–
–
–
ECAD (Electrical Computer Aided Design)
MCAD (Mechanical Computer Aided Design)
Rule checkers (geometric features)
Reports
• Auto-placed components
• Preferred parts
• Cost rollup
•
•
•
•
Manufacturing Readiness Assessment (MRA)
Virtual Prototype Models (visual)
Manufacturing process modeling (discrete event simulation)
Automate where possible
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
4
Early DFx and Producibility Analysis
Reduce Cost Impact
Requirements
System
Architecture
Start Here
In the Future
Requirements
Models
Database
(DOORS®)
Architecture
Models
Architecture
Languages
(OMG SysML™,
AADL,
DODAF)
Detailed
Design
Today’s
Focus
Implementation
& Analysis
Models
Verify &
Validate
Build
Factory &
Supply Chain
Models
Discrete Event
MCAD, ECAD,
Simulator
DFx, Producibility,
(ARENA®)
Visualization,
Cost
Deploy
•
Evolve from focus on
“in series” analysis of
detailed design to
include . . .
•
. . . “in parallel” input
during architecture
trade studies . . .
•
. . . Driving need to
speak the language of
Systems Engineering
OMG SysML is a trademark of Object Management Group, Inc. in the United States and/or other countries.
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
5
Enablers for Early Manufacturing Involvement
Requirements
System
Architecture
Detailed
Design
Build
Architecture
Languages
(OMG SysML,
AADL,
DODAF)
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
Deploy
•
NDIA Manufacturing Division
AMEC Committee
– Spur funding to research
pre-CAD physics-based
producibility measures
•
Georgia Tech “Domain
Specific Language” project
– OMG SysML is the “hub”
for early involvement
•
SAVI (System Architecture
Virtual Integration)
– Formal methods
supplement visualization
Start Here
In the Future
Architecture
Models
Verify &
Validate
6
OMG SysML “Hub”
An Integrated Modeling Vision
mecha Mechanical Architecture
«Mechanical...
HERMES
1..4
«HWCI»
Vehicle
ARENA®
Discrete Event
Simulator
«references-a»
«references-a» «references-a»
«references-a»
0..*
«HWCI»
Remote_Control
0..1
«HWCI»
Data_Loader_V
0..1
«HWCI»
Data_Loader_RC
«references-a»
«references-a» «references-a»
0..3
0..4
«LRM»
Motor w ith
Encoder
«LRM»
NXT
«LRM»
Sensor
«is-a»
«LRM»
Sonar
«is-a»
«LRM»
Color
«is-a»
«LRM»
Compass
«is-a»
«LRM»
Gyro
OMG SysML
“Front End”
User Interface
“Pin 1 Problem” &
Design Rule Evaluation
SAVI
Architecture
Model
SP
2
1
Data Exchange
Reference
Model
Auto-generate
Signature 2
Signature 2
Signature 1
2
AADL, etc.
Supports Formal
Methods Analysis
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All rights reserved.
1
ICD
Model 1
Signature 1
Shared
Property
Model 2
Single Truth
SAVI
Inter-Model
Shared Property
Consistency
Galorath SEER®-H
Parametric Cost
Estimating tool
7
Manufacturing Process Model
in OMG SysML
• Contains all the necessary inputs
needed for an ARENA® model
– BOM, production schedule, resource,
process routings/times
• Shows the graphical representation
of the BOM (Bill of Material) and
each part’s process routing
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All rights reserved.
8
OMG SysML to ARENA® Translation Process
Create an OMG SysML
manufacturing model in
MagicDraw® and then
export the OMG SysML
file (XMI® export).
UML®/OMG SysML
definitions.
UML®
metamodel
XML definitions for
ARENA®.
Eclipse™ Environment
ARENA®
metamodel
Java® script to
format XML file.
(.ecore /
.ecore_diagram)
Java®
(.url)
1
OMG
SysML
model
(.java)
Eclipse™
ATL Eclipse Model-to-
(.uml)
MagicDraw®
2
Unformatted
XML
XSL
(.xsl)
Java®
(.xml)
Model
Transformation™
project
ATL translation
ATL
Transformation
(.atl)
Engine
XML format
definitions.
3
Import the formatted XML file into a prebuilt Access database. The database
contains tables and relationships that are
recognizable by ARENA®. XML data is
placed in the appropriate tables.
4
Formatted
XML
(.xml)
Using the Java® engine within the
Eclipse™ framework, format the
translated XML to a format importable
by Access with a Java® script. This
formats the XML data based on
Extensible Stylesheet Language (XSL)
definitions.
Access®
database
(.mdb)
Java®
Engine
ARENA®
model
(.doe)
ATL translation code
based on the
manufacturing DSL.
Using the Atlas Transformation Language
(ATL) translation engine within the
Eclipse™ framework, translate the OMG
SysML model with the ATL translation
script. During translation, the model’s
UML constructs are compared with
manufacturing DSL and the appropriate
XML semantics for ARENA® are chosen.
Microsoft®
Access®
ARENA®
5 Simulation
Import the database into ARENA®
discrete-event simulation
software. This will create a model
for simulation and analysis.
Eclipse and Eclipse Model-to-Model Transformation are trademarks of Eclipse Foundation, Inc.
Oracle and Java are registered trademarks of Oracle and/or its affiliates. Other names may be trademarks of their respective owners.
XMI and UML are either registered trademarks or trademarks of Object Management Group, Inc. in the United States and/or other countries.
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
9
Translating OMG SysML to ARENA®
• ARENA® manufacturing model
can be simulated to identify
system capabilities/constraints
–
–
–
–
Production (overall/monthly)
Production lead times
Resource capacities
Bottlenecks
• Using these results, decisions
can be made by manufacturing
support teams
© Copyright 2012 Rockwell Collins, Inc.
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ARENA®
model
and statistics
10
Who Uses Process Simulation?
• Boeing
– Used ARENA® to model entire manufacturing and logistics
processes for 787 integration*
•
•
•
•
Assembly lines across the U.S.
Included suppliers of ~50 mechanical components
Simulated Dreamlifter usage for global logistics
Demonstrated potential effects of production ramp-up
• Many medium to large companies use process modeling**
– Examples: Toyota, Ford, GM, Lockheed Martin, NASA, EADS,
Bombardier, Lufthansa, Honeywell, Goodrich, Cessna, Pratt &
Whitney, HP, IBM, UPS
• Colleges and universities
– ARENA® alone is used in over 150 programs in the U.S. and over
500 worldwide
* “Boeing: Integrated Production System Modeling Method” presentation at ArenaSphere 2010 conference, May 17-20, Las Vegas, NV
** Internet search November 2010
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11
Benefits of Process Modeling Projects
•
Tactical applications: allows for elements in a system to be adjusted
without interrupting the current state
•
Strategic applications: allows for new systems to be created and
examined before key decisions or investments are made
•
Provides leadership with a decision support tool to aid in the decision
making process
– Generates data on which to base decisions
– Helps to eliminate “best-guess” scenarios
•
Identifies problem areas so effort can be focused where it will result in
maximum benefit
•
Helps communicate, promote change and receive buy-in from key
stakeholders
•
Gives stakeholders a better understanding of the entire system as a
whole and the interactions that take place within the system
– A model is essentially a living and breathing Value Stream Map!
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All rights reserved.
12
Integration Challenges
• Human Interface
– Graphical user interface – “language” of systems engineers
• Formal methods/analysis – requires semantic precision
• Integration
– OMG SysML is very flexible, graphical interface
– AADL is semantically precise
– MARTE, DARPA META translator: integrate OMG SysML-AADL
• XMI® implementation for tool interoperability
• Automated connection with ERP (Enterprise Resource Planning)
systems
• Need for producibility measures that can be applied during
system design (research)
• Consistency checking of shared properties across model
environments (SAVI – Systems Architecture Virtual Integration)
XMI is a registered trademark of Object Management Group, Inc. in the United States and/or other countries.
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
13
How Can MBSE Address these Challenges?
• Promote and drive toward certified XMI interoperability
– Cax-IF (Computer Aided “x” Implementor Forum) model?
• Architecture language mapping to STEP AP-233
– OMG SysML to AP-233 mapping – is it complete?
– AADL to AP-233 mapping
• Develop a layered systems architecture “data interchange”
model for interoperability between architecture descriptions
– Analogous to OSI (Open Systems Interconnection) model for
communications architectures?
– Abstract systems modeling language at the top (MOF®?)
– Concrete data storage model at the bottom (AP-233?)
– Architecture models can take various forms
•
•
•
•
Language
Instances
Database
File storage
MOF is a registered trademark of Object Management Group, Inc. in the United States and/or other countries.
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
14
Contact
Gregory Pollari
Advanced Manufacturing Technology
Rockwell Collins
[email protected]
319-295-1629
© Copyright 2012 Rockwell Collins, Inc.
All rights reserved.
15
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Manufacturing Process Modeling in Systems Architectures