Category "Digital Factory"

The world has shifted

The current global events is expected to have a significant impact on operating models and business dynamics. Organizations will have to adapt to the new normal and prime themselves for growth in a new environment.

Here are a few quotes from industry experts:

“The COVID-19 Pandemic is fast-tracking Digital Transformation in companies” – Forbes

“Global companies have to be predictive and proactive in their decision-making to preserve business continuity and build enterprise resilience” – Ernest Young

“Generating value while restarting your supply chain” – Bain & Company

“Its not business as usual, so don’t do business as usual” – Gains Group

This is specifically true for a company’s supply chains which are facing multiple challenges. So how does an organization respond to these challenges and reset a supply chain to make it robust and future proof?

Complex scenarios for Supply Chain Reset

It is clear that there will be two major trends for manufacturing companies when it comes to supply chains:

  • A dramatic shift from cost-focused single region limited supply chains to global distributed and diversified supply chains
  • Manufacturing will move from specialized and limited product lines to robust and scalable production lines that can be quickly repurposed

In addition to these trends, Enterprises are facing additional complexities:

  • Current global distributed supplier networks and logistics challenges are an imminent threat to supply continuity, leading to a domino impact on supplies, spare parts and production
  • To secure liquidity, the Just-in-Time production strategy has to adapt quickly to demand fluctuations while accommodating the uncertainties across supply chains
  • Stressed supplier health concerns demand purchase teams to re-evaluate sourcing considerations of supplier health, quality and near term continuity to sustain suppliers

Recognizing the complex supply-demand balance

Apart from the complex scenarios laid out above, supply chain management in the complex new world face multiple uncertainties:

  • Supply chain disruptions – there could be prolonged shutdowns across multiple supply hubs in the world. Also there could be restrictions of movement of parts due to travel restrictions
  • Distressed Suppliers – Many suppliers may be facing financial constraints and liquidity problems. This will force organizations to seek alternatives
  • Sourcing Concentration – Dependence on a single geographic source for supply chains and no clear strategy on mitigation measures
  • Demand Uncertainties – Volatile markets create an uncertain demand and this impacts the entire value chain of a business along with suppliers

A first step – Supply Chain Stress Assessment

So how does an organization start along the road of Supply Chain Diversification and create a network of suppliers that can thrive in the new normal?

The first step is a well orchestrated assessment that fully recognizes the in depth exposure a business has to its current supply chain:

  • Account for all inventory – in-transit, warehouses, spares, inventory buffer
  • Work with immediate suppliers to qualify risks to their suppliers
  • Build “outside in” analytics for all suppliers
  • Run supply chain stress test vs supplier balance sheet to understand vunrabilites
  • Asses whether current or future movement restrictions will disrupt the supply chain
  • Conduct scenario planning to understand how inventory buffer changes will respond to various demand scenarios
  • Task supply chain and operations teams to build multiple plans of supply versus demand and how the plans will play out

A second step – ReSeT

Tata Technologies has devised a framework for an organization to reset its supply chain strategy – ReSeT.

OEM’s need to identify immediate system Restart challenges, devise action plans to Stabilize operations in the medium term and equip themselves to Thrive in the new normal by de-risking supply chains. Business as usual “won’t” be as usaul anymore. To thrive, organizations have to adapt to the new normal

Three Horizons of ReSeT

So what are the actions required for the three horizons?

  • Accounting of Inventory: In-transit
  • Supplier-Assessment: sustained supply in near term and long term
  • Logistics capacity estimation and downstream collaboration with 3PL
  • Alternative Suppliers or distressed supplier management to meet demand
  • Movement of assets like tooling and fixtures to new suppliers
  • Leverage digital tools to enhance upstream and downstream customer collaboration
  • De-risk supply chain trough strategic expansion of local and geographic supply chain
  • Build digital and analytics capabilities for predictive monitoring and supply demand matching
  • Ensure seamless and secure communication with suppliers so that they react to changing circumstances

Tata Technologies – a trusted partner

Tata Technologies brings deep expertise in engineering services and complete digital solutions to assist business navigate through the supply chain rationalize challenges

Tata Technologies has developed a holistic set of tools for supply chain diversification – Optimized Supply Chain and Risk Assessment

  • Assessments of Supply Health, Logistics and Inventory Management
  • Supplier Monitoring, Supplier on-boarding, Demand and supply simulations
  • Supply de-risking strategies, Cost optimization, VAVE, Forecasting tools
  • Digital expertise to build robust systems

OSCAR consists of a combination of digital accelerators and industry expertise.
For a more detailed demonstration, contact Tata Technologies. Or visit our website at tatatechnologies.com

A Virtual Journey in 3DEXPERIENCE

Today’s manufacturers are confronting a rapidly changing business environment. The new reality and relentless competition are having companies re-examine their business models. On Shoring, Near Shoring and diversified Supply Chains are just some of the topics that companies and leaders want to know about.

Tata Technologies has extensive knowledge and expertise in implementing manufacturing technology that will help meet these challenges. We partner with Dassault Systemes to bring world class solutions to our customers.

Launching on July 29th, 3DEXPERIENCE: A Virtual Journey, is an online series designed to help companies transform their business with episodes focusing on industry leading strategy and insight – ready to stream anytime, anywhere. Discover how to bring together all aspects of business to increase collaboration, improve execution and accelerate the transformation to full digital continuity. Learn how to make your business accessible from anywhere with real-time collaboration for your entire team

Register now and join us July 29th for the live plenary session at 1:00 EDT. This will be followed by release of episode 1 –
3DEXPERIENCE: A Virtual Journey

It’s all about Risk Mitigation. The quote you most often hear is “better as-built data leads to better designs”. It’s clear now that laser scanning
is a better workflow vs field measuring. Frequent trips to get it right can’t replace one trip to get it right the first time. We always hear theScan and CAD
devil is in the details and laser scanning, done right, records the details.

Field measurements, outdated documentation, delays, and travel time, all lead to inaccurate and late proposals. Once the proposal is accepted it’s up
to you to keep the project profitable. In some documented studies working from a laser scan has reduced rework to less than 2%.

Some benefits include:
• Provide access to the point clouds for all stakeholders, everyone is working from the same information
• Reduce the number of incidents from manual measurement errors.
• Reducing time onsite
• Fewer mismatches and design errors
• Advanced interference and clash detection for installations without onsite visits
• Consistent as-built documentation for design specifications

There is no doubt that working in 3D space is better than 2D alone. The issue has been getting to a 3D environment. Laser scanning provides this
in an economical and timely manner.

Tata Technologies is an engineering services company dedicated to engineering a better world. Visit our website at www.tatatechnologies.com

There is so much more to this command than welding. Not only is there a full range of weld types, but you can also model beads of adhesives, glue, and mastic as well as fasteners like rivets for example. Basically there are three categories in Weld Assistant for joining parts, they are: discrete welds, line welds, and adhesives. Normally a rivet is a type of fastener, but they are included as a custom weld in Weld Assistant.

In this post, let’s take a look at how to model rivets. We will create a custom spot weld to mimic a rivet. We will start by configuring a custom weld spot under File + Utilities + Customer Defaults.

  • From the Customer Defaults window, select Weld Assistant + Point Locator and then select one of the Custom tabs.
  • Set the Solid Display to Cylinder and give the custom Point Locator a name… Rivet for example.
  • Set the other attributes accordingly, and then select OK to finish the configuration.

Now create a Rivet the same way you would create a Resistance Weld Spot.

  • From the Weld Assistance command select Weld Point Wizard.
  • From the Weld Point Wizard block:
    • Select your Method
    • Set the Type to the new custom Point Locator you just created (i.e. Rivet)
    • Select Next.
  • Select the Face Sets and then select Next
  • Select the points you want to create Rivets at and then select Next.
  • Select Finish to place the Rivets.

If the Rivets don’t show up at first, then select the Solid Weld Point Display option.

Key benefits to modeling welds in Cad include:

  • Provides a key piece of information necessary for a complete Digital Twin.
  • Mass properties inclusion (Weight and Volume).
  • Easy to visualize.
  • Easy to validate for correct location using Weld Advisor.
  • Easy to convey information via a Drawing or PMI
  • Available for inclusion into CAE analysis
  • Available for process planning
  • Available for robot programming
  • Significant time savings compared to manual application of welds
  • Having the ability to create and validate the Rivets in CAD ensures quality data is being sent to manufacturing thereby reducing the amount of rework.

Visit www.tatatechnologies.com or contact info.americas@tatatechnologies.com

Do any of the questions below apply to your organization:

  • Do you own existing Dassault Systemes software products and are up to date with maintenance?
  • Do you need to transform your digital engineering processes?
  • Are you interested in implementing the true Digital Twin concept?
  • Is the technology that you are using for Digital Product Definition out of date?
  • Does your company have strategic initiatives like Lean Manufacturing, Flawless Launch, Model Based Engineering or similar?
  • Is your company expanding or looking to put new products on the market?

If the answer to any of these questions is Yes, then you should be looking at the Customer Transformation Program (CTP) from Dassault Systemes.

Dassault Systemes  launched a Customer Transformation Program for 2019 which is designed to transform the businesses of all their existing customers. This is a limited-time sales initiative program starting January 21, 2019 and ending December 31, 2019.

The program offers existing customers a voucher that makes them eligible for a discount on qualified new purchases of software from Dassault Systemes extensive range of productivity enhancing solutions. Customers can earn up to 35% off purchase of qualified new software – an exciting incentive to get up to date with the latest technology.

The future focus of Dassault Systèmes is on the innovative 3DEXPERIENCE platform, a disruptive technology that can completely transform your business. As a result, the largest discounts are for platform products, on premise or in the cloud.

As an example, a customer may have an existing Dassault Systemes CATIA V5 software and his installed base entitles them to a voucher good for 35% discount on a new product up to an amount 0f $35,000. Assume a new opportunity arises and the customer requires SIMULIA to run advanced simulations. If the list price of what is required is $100,000, then this can be purchased for $65,000 by applying the voucher.

As a trusted advisor, Tata Technologies can help navigate through the CTP program. Dassault Systemes has been investing billions into innovative technologies and helping organizations face business challenges. Please engage us to discover how your business can be transformed.

Visit www.tatatechnologies.com or contact info.americas@tatatechnologies.com

Does your organization rely on creating and using CAM (Computer Aided Machining) programs? Do you have difficulty keeping track of all your CAM data? Do you struggle with quality issues in your machining operation? If the answer is yes, you could benefit from a Machining Benchmark.

The Machining Benchmark assessment captures the opinions of senior and knowledgeable personnel in your organization on the current state and future Machining requirements for your business. In addition, a priority for improvement and an assessment of current effectiveness is recorded. It centers on 17 key Machining “Pillars” ranging from PLM Training, through to Automation and Development. The pillars are listed below:

  1. CAM Programming Capabilities
  2. CAM Maturity
  3. CAD/CAM/CNC/CMM Integration
  4. Tooling and Fixture Design
  5. CAM Best Practices
  6. CAM Validation and Simulation
  7. CAM Efficiency
  8. Version and Revision control of CAM data
  9. Supplier Collaboration
  10. Shop floor Documentation
  11. Model based Definition
  12. Quality Management
  13. Dimensional Control
  14. CAM User Support
  15. CAM Application Maintenance
  16. On boarding for CAM systems
  17. Ongoing training for CAM systems

After the 17 pillars have been covered, senior and knowledgeable personnel are also invited to “spend” an assumed benefit in value areas within your business. The areas identified are improving time to market, increasing the portfolio of the company and improving product quality.

Finally, the tool produces a comprehensive report showing the customer’s current state of maturity and a benchmark comparison with the industry.

Participants have found this process to be very useful as it allows them to prioritize their initiatives, gives a high-level view of their roadmap to success and provides them with industry benchmark information.

Does your organization struggle launch a product into manufacturing? Do you have costly launch cycles that overrun both budget and time? If the answer is yes, you could benefit from a Digital Factory Benchmark.

The Digital Factory Benchmark assessment captures the opinions of senior and knowledgeable personnel in your organization on the current state and future Digital Factory requirements for your business. In addition, a priority for improvement and an assessment of current effectiveness is recorded. It centers on 17 key Digital Factory “Pillars” ranging from Factory as Built, through to Robotic programming. The pillars are listed below:

  1. Factory As-built
  2. Digital Factory
  3. MBOM
  4. Process Planning
  5. Assembly Simulation
  6. Work Instructions
  7. Ergonomics Task Definition
  8. Ergonomic Analysis
  9. Manufacturing time library
  10. Resource Modeling
  11. Production Line Simulation
  12. Materials flow
  13. Factory infrastructure optimization
  14. Robotic offline programming
  15. Robotic Simulation
  16. Robotic Arc Welding
  17. Robotic Spot Welding

After the 17 pillars have been covered, senior and knowledgeable personnel are also invited to “spend” an assumed benefit in value areas within your business. The areas identified are improving time to market, increasing the portfolio of the company and improving product quality.

Finally, the tool produces a comprehensive report showing the customer’s current state of maturity and a benchmark comparison with the industry.

Participants have found this process to be very useful as it allows them to prioritize their initiatives, gives a high-level view of their roadmap to success and provides them with industry benchmark information.

Are you looking at investing in a MES (Manufacturing Execution System)? Do you need to improve the efficiency of your manufacturing operations with the latest technology? If you answered yes, then a MES benchmark may be exactly what is needed.

In order for you to realize the value from your current or future MES investments, you must first understand the maturity of your business and your current state. In addition, you must identify a pragmatic future state and plan a roadmap to achieve it. This may involve not only introducing new technologies and processes, but changes to your organization to support them.

Tata Technologies has developed a structured MES Analytics process with supporting tools and processes to help our customers understand the maturity of their MES, compare it to their peers and plan for the future.

The MES Benchmark assessment captures the opinions of senior and knowledgeable personnel in your organization on the current state and future MES requirements for your business, together with a priority for improvement and an assessment of current effectiveness. It centers on 17 key MES “Pillars” ranging from Scheduling Management, through to Shipping. These pillars are listed below:

  1. Enterprise Resource Planning (ERP) Integration
  2. Product Lifecycle Management (PLM) Integration
  3. SCADA, Control and Interfaces
  4. Inventory Management
  5. Planning, Scheduling and Execution
  6. Resource Management
  7. Progress Tracking
  8. Track / Traceability / Genealogy
  9. Error Proofing
  10. Quality Management
  11. Recipe Management
  12. Work Instructions
  13. Shipping Management
  14. Shop floor Information
  15. Data Collection and Performance Analysis
  16. Maintenance Planning and execution
  17. Predictive Analytics

After the 17 pillars have been covered, senior and knowledgeable personnel are also invited to “spend” an assumed benefit in value areas within your business. The areas identified are improving time to market, increasing the portfolio of the company and improving product quality.

Finally, the tool produces a comprehensive report showing the customers current state of maturity and a benchmark comparison with the industry.

Participants have found this process to be very useful as it allows them to prioritize their initiatives, gives a high-level view of their roadmap to success and provides them with industry benchmark information

My previous post described the “Digital Twins” in general and the importance of PLM to support it. To begin with a Digital Twin need to provide the means to design, validate and optimize a part, product, manufacturing process or production facility in the virtual world using a set of computer models. It should enable companies to do these things quickly, accurately and as close as possible to the real thing – the physical counterpart. They also need to consume the data from sensors that are installed on physical objects to represent their near real-time status, working condition or position.

Digital Twins was in the making for many years , especially around advanced robotics. Siemens has recognized the value of the digital twin for a long time and enabled the development of full 3D models for automotive body assembly cells. These models were used to simulate, validate and optimize robotic operations before they were executed on the shop floor. With an extremely high degree of fidelity, these applications could not only simulate a cell, but also enable its near perfect virtual commissioning. Advances in computer science have made it possible to broaden the scope of the primitive digital twin to include many more capabilities, information, inputs and outputs. Today Siemens support digital twins for product design, manufacturing  process planning and production using the Smart  Factory loop and via smart products.

One of the most important value of a digital twin is that it enables flexibility in manufacturing and reduces the time needed for product design, manufacturing process and system planning, and production facility design; thus helping companies to develop and introduce new products to the market much faster than ever.  Connecting Engineering , manufacturing process design and actual production is the foundation and starting point for Digital Twins.

A digital twin also improves quality and even supports new business models that offer opportunities for small-to-midsize companies to expand and bring more high-tech capabilities into their shops. Digital twins will help companies become more flexible,  reduce time-to-market and costs, improve quality and increase productivity at all levels of the organization.  When implementing a true “Digital Twin” on the first day becomes a  big ask for companies,  they might want to adopt it in a phased manner, may be in a similar way it evolved – starting with automated manufacturing process design and production.  My next blog will outline the three pillars involved in deploying a digital twin .

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