[step-manufacturing] Mukilteo meeting report and results

[Martin Hardwick]

All,

There is now an archive of the Mukilteo meeting results at the URL 
below. This will be moved to ap238.org when it is ready.

ftp://downloads.steptools.com/private/JWG15/Mukilteo/meeting/

A meeting summary is copied below and can also be found in the archive.

Please let me know if there are any additional results that I should add 
to the archive.

Martin Hardwick
Convener WG15


  Digital Thread Demonstration – October 5^th , 2016

The Digital Manufacturing working group of ISO TC184/SC4 met at the 
Future of Flight museum in Mukilteo, Washington from October 3^rd to 6^th.

On October 5^th they gave a demonstration.

·A standards based digital thread was used to update a machining “twin” 
model in real time.

·The machining model was measured using on-line software, and off-line 
using a CMM.

·New automations become possible when machining is measured in real 
time. They showed the feeds being made 15% more efficient by monitoring 
chip thickness.

Machining which was taking place in the Boeing Renton plant 30 miles 
away was modeled in a digital twin in Mukilteo. The twin was measured in 
real time in the room where the demonstration was taking place, and in 
the basement where a CMM had been installed for that purpose. The model 
included design requirements and process plan data. At each stage of the 
process plan, the machining results were checked against the design 
requirements for that stage.

The machining was tracked at a rate of 100 times a second (100 Hz). This 
compares to the 60 times a second that a typical computer screen is 
refreshed. The real-time was validated using a camera in the machine 
that showed the same machining movements as the simulation. Design 
requirements were communicated using the STEP AP242 protocol. 
Manufacturing solutions were communicated using the STEP-NC AP238 
protocol. A digital twin was built from an MTConnect stream delivered 
over the Internet from the machining system. The digital twin was 
measured for conformance to its design requirements by real and virtual 
CMM’s. The measurement results were sent to assembly using QIF.


Takeaways from the demonstration include:

•The digital thread reduces costs by enabling the use of cloud services

–Services to generate and optimize machining and measurement solutions

–Services to select machines and cutters, and optimize the schedule

•The digital thread enables scientific shop floor control

–Manufacture faster when the schedule is tight

–Manufacture with less tool wear when the schedule is open

•The digital thread enables real-time measurements and adjustments

–Change process for actual stock sizes, validate changes from smart phones

–Deliver digital data for assembly simulation and digital assembly

•The digital thread enhances the product

–Designers, planners and machinists share results and see each other’s 
solutions

–Maintenance and third parties see requirements and help optimize solutions


    A second demonstration is being planned for February in which a tool
    wear issue will be identified by monitoring power consumption and an
    operator will be “tweeted” to come and check dimensions before
    machining continues. A third demonstration in July will integrate
    additive and subtractive manufacturing.


    Acknowledgements

The demonstration was made possible by the Digital Design and 
Manufacturing Innovation Institute (DMDII) in two projects known as 
“Mind the Gap” (14-02-02) and “O3” (14-06-05).



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