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Design007-Apr2019

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18 DESIGN007 MAGAZINE I APRIL 2019 Assemblers have been driven to reduce or eliminate finished goods stock from the warehouse all the way through to the cus- tomer with direct shipping preferred over the investment of stock in an expansive distribu- tion chain and risk of depreciation as market demands change. This is in part a great op- portunity for the resurgence of local manu- facturing and a key driver of Industry 4.0. The assembly schedule, therefore, has to meet the almost daily requirements of the customer, over the complete range of prod - ucts made. Hence, the high-mix and low-vol- ume scenario. As this is a long-term significant business driver, assembly cannot continue to cling to the paradigm of optimized long-term planning as core parameters change every day. What is really needed is a way to manage the allocation of products to assembly line configurations im- mediately in a way that optimizes the utiliza- tion of resources. Accepting that we have to visit individual stores on the high street does not preclude us from planning to visit them in an efficient fashion, creating a sequenced jour- ney that minimizes the walking distance from one to another. Having seen the evolution of the core busi- ness requirement, Aegis Software has been driving industry change through the use of new technology based on standards for some time. Assembly engineering and manufacturing are now going through a fundamental change to address the production fragmentation prob- lem. Adaptive planning is a critical new solu- tion within a modern digital engineering solu- tion. The best practice flow is to receive the complete product design data inclusive of all required documentation related to the intent of how a product should be built. This is best achieved through the easily se- cured, single-file IPC-2581 digital product mod- el (DPM) design data exchange format. The digital engineering solution then assigns as- sembly work required in the design to any ca- pable production configuration, often on de- mand, which meets the changing customer need. Lines selected to make the product need to receive a reliable standard form of infor- mation with which the machines can be eas- ily and quickly prepared without the need for lengthy teaching, learning, or any significant data translation. The combination of the IPC-2591 Connect- ed Factory Exchange (CFX) standard and the IPC DPM achieves this with the digital engi- neering solution providing the necessary envi- ronment and tools. The digital MES also utiliz- es CFX to create visibility of production status and events so that available line configuration opportunities can be identified. This is done with consideration of live optimization of the overall factory and product flow as well as of the supply-chain material availability and lo- gistics to and from machines. The net result is the ability to execute a production job from receipt of design to the start of manufacturing on any line configuration in a mere fraction of the time traditionally required, eliminating much of the manufacturing downtime associ- ated with process preparation. The opportunity for design is created from this new assembly digital engineering para- digm. What happens in the process of assem- bling a product has great value in the assess- ment of the design itself in terms of product quality—both during assembly and in the mar- ket—as well as long-term reliability. The use of IPC CFX and DPM standards as part of the digi- tal MES environment means that data related to the choice of materials, process settings, test measurements, etc., can be gathered far more quickly, accurately, and consistently. As this is a long-term significant business driver, assembly cannot continue to cling to the paradigm of optimized long-term planning as core parameters change every day.

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