Boeing STEP Manufacturing Program

1. Boeing STEP Manufacturing Program NASA’s STEP for Aerospace Workshop King G. Yee January 18, 2001

2. Agenda Process Today Process Tomorrow Future Development Summery

3. ARC INSIGHTS, January 10, 2001

4. The international Standard for Product Model Data (STEP ISO 10303) completely defines the information used by engineering and manufacturing activities throughout a product life cycle. STEP standards development has extended their reach onto the shop floor by attacking the CAM (Computer Aided Manufacturing) and CNC machining standards. Specifically, STEP-NC, ISO 14649-11, is an extension to STEP that seeks to displace the existing G code formats specified in by RS-274-D/DIN 66025 standards. Effectively, STEP-NC makes the “post processor” on CAM systems obsolete. A single data format for the CAD and the machine will coexist to enable information to flow from the ma-chine tool to upstream design tools. STEP-NC is a feature-based language being tried as a G code replacement. Basically, it retains the original design features of mechanical components or fabricated metals in the executable instructions brought to the machine tool on the manufacturing floor. The STEP-NC specification coupled with XML promises to connect CNCs to the Internet and streamline the NC machining process. Combining these technologies will offer ma-chine tool geometry platform independence, better product model data exchange, and new levels of manufacturing collaboration. An XML standard schema is being developed for STEP-NC. This standard will insure that all data in a product model is tagged in a manner consistent with the machining operations defined by the STEP-NC specifica-tion. Essentially, XML provides a very convenient way to link manufacturing processes, tool paths, and tool selection information with geometry, features, and machining steps in the database. This will prove to be one of the emerging technologies that will enable collaborative e-manufacturing to become a reality on the plant floor.

5. Automated NC Machine Parts Process “Today” Unigraphics Conceptual Engineering Concurrent Design/Solid Modeling and Manufacturing Planning Standard ANC Templates Genius Mfg Database Engineering Part Solid Modeling With Removal Volumes STEP AP203 Engineer Automated NC Digital Product Definition VNC Tool Path Generation NC Programming Develop Digital Pre-Plan ANC Develop Manufacturing Removal Volumes Programmer Digital NC Plan UG CAM Machine Simulation Develop Initial Manufacturing Strategy Machine Part

6. Automated NC Machine Parts Process “Tomorrow” Unigraphics Conceptual Engineering Concurrent Design/Solid Modeling and Manufacturing Planning Standard ANC Templates Genius Mfg. Database Engineering Part Solid Modeling With Feature Identification Pocket Hole Profile STEP AP203 Engineer Automated NC Digital Product Definition VNC Tool Path Generation Manufacturing Features STEP AP224 Develop Digital Pre-Plan ANC Develop Manufacturing Features Programmer Hole Tool Tab Slab Digital NC Plan UG CAM Machine Simulation Develop Initial Manufacturing Strategy Machine Part

7. Automated NC Machine Parts Process “Tomorrow” Unigraphics Conceptual Engineering Concurrent Design/Solid Modeling and Manufacturing Planning Standard ANC Templates Genius Mfg. Database Engineering Part Solid Modeling With Feature Identification Pocket Hole Profile STEP AP203 Engineer Automated NC Digital Product Definition VNC Tool Path Generation Manufacturing Features STEP AP224 Develop Digital Pre-Plan ANC Develop Manufacturing Features Programmer Hole Tool Tab Slab UG CAM Machine Simulation STEP AP 213 Develop Initial Manufacturing Strategy NC Process Plan Machine Part

8. Common Data Format For Manufacturing “Vision” (CAD System) CATIA PRO-E CommonData Format ANC Process UG • Standardized (STEP AP203/AP224) • Platform Independent • Complete • Manufacturing Enhanced • Unambiguous CV

9. Product Model Manufacturing Features Tolerance Data A Single, Complete, Consistent, Standard, and Unambiguous Manufacturing Feature Definition. AP 224 File QA-ANC ANC ADVICE Man. / Assem. Costing Automated NC ISPC Automated Quality Assurance Process Based SPC ANC Supplier Int. STEP NC Advanced Machine Controllers Supplier Capability Analysis Feature Tracking Between CAD/CAM Systems Production Process Analysis Optimization of Factory Resources Automated Producibility Analysis Manufacturing Vision

10. Inspection AP 219 AP 224 manufacturing features AP203 Design Controller ISO 14649 workpiece tool path Detailed NC Process Planning Process Planning Tool Path Generation Milling AP 213 stock fixtures #setup machine …….. …... AP 213 tools AP 213 Simulation feedback Development Manufacturing Machine Code Data Turning Manufacturing Plan

11. NC Process Planning To fully take advantage of STEP-NC and the open NC Controller, AP 213 must be enhanced To support both dimensional and geometric tolerances (if AP 213 is enhanced with AP 224 tolerances the validation activity can support inspection process ). To support STEP-NC (current AP 213 spec references the traditional “M” and “G” code standard). To support the 2nd edition STEP integrated resources (IR) and to harmonize with PDM.

12. Harmonization of Standardsfor Manufacturing All manufacturing standards need to be consistent and harmonize machining features, dimensional tolerances, and geometric tolerances for a successful exchange of product data throughout the manufacturing life cycle. To ensure consistency, all manufacturing application protocols need to have the same product structure, the need to be harmonized with the PDM Schema.

13. Backup

14. UK RAMP • SCRA’s STEP AP224-based technology used by UK MoD for several years • Significant pilot project just completed • 585 parts processed planned • 171 parts manufactured • Successful! Rolling out a UK RAMP Center • MoD is calling out AP224 as preferred tech data

15. ALTERNATIVE SCENARIO UK MOD AP 224 XML Business Case XML XML Netscape AP203 3-D Geo Design AP 224 Geo +Features ANC