Demystifying Digital Continuity in 3DExperience ManufacturingPublished On - July 31, 2018 Michael Finocchiaro 3DExperience 3DExperienceOne of the mysteries in the PLM world for me – coming from more of a graphics / CAD-centric background – has been manufacturing. During my ten years of working with DS products, I had friends in DELMIA without every fully understanding all that it did and thus it got little coverage in Demystifying 3DEXPERIENCE and my 3DEXPERIENCE video. This post aims to correct that.First off, what I have gleaned from the various presentations that I have sit through and read is that the overall vision for Dassault Systèmes is to take core activities that were done in ERP like routing, MBOM, and work instructions and move them up into PLM including management of factory resources and consumables. This, in effect, moves the line between PLM and ERP further towards manufacturing execution (much of which is covered partially by current DELMIA Apriso, DELMIA Ortems and QUINTIQ products that are currently not directly on the 3DEXPERIENCE platform). In fact, we can now speak of “Virtual Build” – where you define a sequence of steps in a manufacturing process and the system automatically creates the 3D required for visualizing it on the fly with dedicated graphical indicators highlighting manufacturing process steps and also supports integrated simulation studies such as for ergonomics or robotics– this represents potentially a radical reduction in time for moving from physical to virtual world in PLM!There are two easy to understand scenarios where this vision becomes reality:BODY IN WHITE FOR AUTOMOTIVE3D CATIA modeling of fasteners representing weld points directly on the Assembly Structure of the body frameDirect consumption of CAD-based fasteners within the MBOMDirect and intelligent consumption of Fasteners w/in MBOM into Process Planning (PP), enabling optimizations such as line-balancing for weld operations as well as intelligent selection of weld gunsDirect use of Fasteners organized by PP “Operations” to automatically program and simulate Robots and generate controller specific executables per robotFeeding robot programs in their native format into robot controllers on the shop floorandFULLY DIGITAL 3D MASTERCATIA modeling of all aspects of engineering specifications which reflect requirements to manufacturing (tolerance, finish, torque values, etc.) via FTA (3D Annotations)Publishing of these specifications as PLM requirements in 3DEXPERIENCE platform maintaining links to original product definitionDirect consumption of specification-based “Requirements” into MBOM and PPDirect use of Requirements within auto-generation of 3D Work Instructions to be performed by humans on shop floor – ORDirect use of Requirements within auto-generation of machine operations leading to NC Program generation and post-processingResults of either of the above are fed via MBOM to people or machines performing the work in the context of a scheduled production orderWe can see that this enables the PLM system to simulate and directly feed both people and machines on the shop floor resulting in massive gains in precision, time and cost.A BRIEF HISTORYIn 1997, Dassault Systèmes acquired DENEB Robotics (Manufacturing Simulation) and in 2000 they acquired both SAFEWORKS (Ergonomics) and DELTA (Process Planning). The result of these acquisitions was the birth of the DELMIA brand in 2000 aimed initially at virtual manufacturing. The new apps used a data model derived from the same one used by CATIA at the time. Since then, many other acquisitions such as, more recently, DELMIA Apriso, DELMIA Ortems, and QUINTIQ have fleshed out a broad manufacturing footprint for the DELMIA brand pushing the envelope to include manufacturing execution, scheduling, supply chain optimization, and many other areas that were traditionally ERP vendor domains.During the V6 era, as described in my Demystifying Digital Thread and Digital Twinarticle as well as Demystifying 3DEXPERIENCE Customization, there were two data models inside the platform – one for the rich clients (CATIA, SIMULIA, and DELMIA) and one for the web-based clients (ENOVIA based on MatrixOne). In the rich client world, the waterfall process including Requirements-Functional-Logical-Physical (RFLP) for CATIA, Model-Simulation-Result (MSR) for SIMULIA, and Product-Process-Resource (PPR) for DELMIA were (and are still) all based on the same basic data model. For the BOM however, this actually presented some significant pain for customers because the Engineering BOM (EBOM) was owned by ENOVIA who also had their own Manufacturing BOM (MBOM) the data model for both of which of which were incompatible with the Product Structure in CATIA and the PPR model in DELMIA. This meant that there was a massive gap between the engineering world and the manufacturing world and customers had multiple issues trying to span their enterprise from design through engineering to manufacturing using a pure-DS stack where the MBOM was concerned.3DEXPERIENCE R2017X AND R2018X IMPROVEMENTSWith the changes in Enterprise Change Management (ECM) and POWER’BY that were rolled out starting in 3DEXPERIENCE R2017x and R2018x, there is a CATIA/DELMIA compatible EBOM called “Unified Product Structure” which is consistent and compatible with the DELMIA Manufactured Item (or MBOM) making true digital continuity a reality as was never before possible. Change Management under ECM is also unified across all business and engineering domains. Now, the digital continuity is maintained from design, through engineering and simulation onto manufacturing enabling true cost and time savings.There have also been many improvements around 3D Printing support and therefore processes around Additive Manufacturing have not been ignored. The big advantage of Dassault Systèmes in this domain is their ability to cover the chemical & material aspects with BIOVIA, the design with CATIA, the simulation with SIMULIA and the manufacturing the DELMIA – each of which has dedicated products and roles for additive manufacturing such as the new 3D Printer resource for DELMIA Process Planning.THE CRYSTAL BALLGoing forward, it would seem that the Dassault Systèmes’ goal is to maintain full digital continuity from Requirements to Manufacturing/Production (RLFP-MSR-PPR) for ALL Engineering Design domains:Engineering Design, Analysis, & SimulationSystem Modeling & SimulationManufacturing Operations Management – tighter integration with DELMIA AprisoSupply Chain & Scheduling – integration with DELMIA Ortems (acquisition from June 2016) and QUINTIQThe end result will be a nearly impregnable and consistent footprint from design and engineering through simulation to manufacturing execution delegating financials, human resources and payroll to the ERP systems. It is a compelling story that will accelerate bringing the most innovative products to market with the latest and most efficient manufacturing methods. DS has significantly broken down more traditional silos with the net result being even further reduced time to market and reduced cost of reaching quality thanks to all the simulation validation happening earlier in the process, and also thanks to the heightened level of collaboration across the enterprise.Michael Finocchiaro is an independant 3DEXPERIENCE consultant and evangelist and currently the Chief Architect in Residence at XD Innovation.At XD Innovation, every product begins with an idea and we provide the tools to make them a reality. @XDInnovation is a Dassault Systemes Value Solutions Partner focused on software, consulting and value added services for product development technologies, enabling 3D Design, Engineering, 3D CAD, Modeling, Simulation, Data Management, Process Management, Quality & Compliance. We strive to help our customers innovate more efficiently by providing best in class technologies powered by Dassault Systemes 3DEXPERIENCE PLATFORM and backed by a consultative customer engagement approach, a rapid implementation methodology and superior training and support.