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Model-Based SE Using SysML Part 2: Integrating Manufacturing Design and Simulation

NDIA Systems Engineering Division, M&S Committee April 22, 2009  Washington, DC. Model-Based SE Using SysML Part 2: Integrating Manufacturing Design and Simulation. Leon McGinnis Georgia Institute of Technology Product & Systems Lifecycle Management Center www.pslm.gatech.edu.

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Model-Based SE Using SysML Part 2: Integrating Manufacturing Design and Simulation

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  1. NDIA Systems Engineering Division, M&S Committee April 22, 2009  Washington, DC Model-Based SE Using SysMLPart 2: Integrating Manufacturing Design and Simulation Leon McGinnis Georgia Institute of Technology Product & Systems Lifecycle Management Center www.pslm.gatech.edu

  2. GIT Product & Systems Lifecycle Management CenterLeveraging Related Efforts www.pslm.gatech.edu • SysML-related projects: • Deere, Lockheed, Boeing, NASA, NIST, TRW Automotive, ... • Other efforts based at GIT: • Vendor collaboration (tool licenses, support, ...) • Keck Virtual Factory Lab • SysML course development • For Professional Masters in SE program, continuing ed. short course, ... • ASDL in AE • Tennenbaum Institute for Enterprise Transformation • Consortia & other GIT involvements: • OMG (SysML, ...) • PDES Inc. (MBE, APs 210, 233, ...)

  3. Excavator Modeling & Simulation TestbedTool Categories View

  4. Model-Centric FrameworkProduce, Merge, Enrich, Consume http://eislab.gatech.edu/pubs/journals/2004-jcise-peak/ (where “collective product model”  “federated system model”) Tool A1 Tool An ... Producer Tools (Primary Authoring) • Federated System Model • Meta-Building Blocks: • Information models & meta-models • International standards • Industry specs • Corporate standards • Local customizations • Modeling technologies: • Express, UML, SysML, COBs, OWL, XML, … Enricher Tools (Secondary Authoring) Tool Bj Tool Ck Consumer Tools (e.g., Solvers)

  5. Excavator Modeling & Simulation TestbedInteroperability Patterns View (MSI Panorama per MIM 0.1)

  6. My focus today: • What does it mean “to integrate manufacturing with design?” • What does it mean “to integrate manufacturing system design with manufacturing system simulation?” • How can we make these two things happen?

  7. Integrating Manufacturing and Design ? ? ?

  8. Integrating Manufacturing and Design ? ? ?

  9. Product Models in CAD

  10. Product Model(E-BOM vs M-BOM) M-BOM E-BOM

  11. Design to Manufacturing Integration • EBOM to MBOM Transformation • Or “EBOM to WBS” • More than “interoperability” or “converting a file format”; “how” based on “what” • Sourcing (=> logistics, cost, schedule …) • Resource organization/assignment (=> mfg cost) • Inventory/WIP positioning (=> cycle time …)

  12. R&D Strategy • Conform factory design to product design • Functional design • Detailed design • Recognize process planning as the “design to manufacturing” bridge • Manufacturing as part of a federated “enterprise” model

  13. Factory Design Capabilities

  14. Design Data: EBOM + MCAD

  15. Functional Design for Manufacturing Process—SysML Use Cases

  16. Resource Model & Layout Model Tool Instance Data in Excel Factory Layout in FactoryCAD(AutoCAD) Bill of Resource in SysML

  17. SysML Ref. Model  FactoryCAD Library SysML Reference Model FactoryCAD Library Shape Drawing 20

  18. Layout Using F-CAD Library from SysML FactoryCAD Library Layout Drawing Select/ Place 21

  19. Capturing Layout Information Layout Drawing Database Extract SDX Xpath Parser Study DB 22

  20. Observations • Factory design is driven by: • What • How much • When • Where • So how do we integrate those issues? • Use SysML Activity Diagrams to capture how we intend to use manufacturing resources to create the product

  21. Process Planning Model

  22. Detailed Process Planning

  23. Operation Allocation <<Allocate>> <<Allocate>> <<Allocate>> 26

  24. Manufacturing Process Model

  25. Activity Diagram to MBOM Transformation Automated Transformation

  26. BOM Transformation using Moflon Meta-model level based on MOF (Modeling) Application independent BOM Transformation rule Activity Metamodel BDD Metamodel Correspondence + SD described by MOF Integrator based on JMI level (Execution) Source model JMI Transformation Rule JMI Target model JMI XMI Adapter MD Adapter MD Adapter XMI Adapter Magic Draw Link information Magic Draw JMI Data Repository

  27. Manufacturing Model Interdependencies

  28. Summary

  29. Federated Model Interfaces Excel: Vendor Tool info Process Plan Manual MD BDD: E-BOM Tools Layout M-BOM C# C# E+ FactoryCAD Library Library Moflon C# Excel FactoryCAD drawing MD Activity Diagram MD BDD Instance MD BDD : Factory Organization Access Tables eM-Plant script Simulation eM-Plant

  30. Conclusion • SysML and formal models enable a formal interoperability between product design models and factory design and process planning models. • Not clear yet how to make the connection the other way…future R&D

  31. Simulation Capabilities

  32. Analysis Requirements Create and Run Model Results Fundamental Problem in Factory Simulation Factory simulation is not directly accessible by factory engineers.

  33. Observations • Factory engineers must “author” requirements • Simulationists must determine a process for converting “requirements” into “simulation code” • We can automate what simulationists do if it conforms to a repeatable (learnable) pattern.

  34. Proposed Factory Simulation Framework On-Line User COTSAuthoringTools DescriptiveModelLibraries Results ModelTranslator AnalyticModelLibraries FormalDescriptiveModelInstance FormalAnalyticModelInstance COTSSolver 37

  35. Proposed Factory Simulation Framework Off-Line User Modeler DescriptiveModelLibraries ModelTranslator AnalyticModelLibraries 38

  36. Proposed Factory Simulation Framework 39

  37. Factory Model Concept Block Block Block Block State1 action1 action3 action2 State2 SystemStructure State1 SystemBehavior State2

  38. Factory Structure Tool Instance Data in Excel Factory Layout in FactoryCAD(AutoCAD) Bill of Resource in SysML

  39. Behavior Modeling Entity-Job Complete Lot Control System Notify Dispatch Control system Idle [When notified] Dispatch event Dispatching

  40. Behavior Modeling-state machine diagram

  41. Behavior Modeling-Sequence diagram example

  42. Simulation Generator--Structure = +

  43. Simulation Generator--Behavior + =

  44. Implementation Challenges • NOT structure—NIST CMSD is one start toward a practical standard for structure • Modeling Control! • State machine/Sequence Diagram? • Activity Diagram? • Executable UML? • What’s the fundamental conceptual model? • Moore machine • Mealy machine • DEVS • Other?

  45. If you want to play this game • Formal languages • SysML is our bet • Model transformation • MOFLON? QVT? We’re not completely sold… • Implicit/Explicit paradox • Domain specific languages • Profiles of SysML

  46. Conclusion • SysML and formal models (potentially) enable an unprecedented integration of manufacturing system “description” and manufacturing system simulation (like the MCAD and ECAD domains now enjoy) • Rationalization of factory control remains the fundamental challenge—how can we reconcile the complexity of real factory control with the need to create (in finite time and finite cost) useful factory simulations?

  47. Main Questions Addressed by Project Process: How do we include engineering analysis tools in the MBSE process? Representation: How do we represent engineering analysis models in SysML? Execution: How do we integrate engineering analysis tools & models with SysML tools & models? 50

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