Munitions Manufacturing A Call for Modernization (2002) / Chapter Skim
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4 Product Realization
4 Product Realization
Pages 57-74
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From page 57... ...
At, , _ . _ For years manufacturers have dreamed of a computerized, integrated product realization process extending from initial concepts through mechanical design, process planning, costing, production, and beyond.
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From page 58... ...
TIME plans to accomplish many of its goals through a phased set of technology integration, validation, demonstration, and development activities that includes efforts to accomplish the following (Bur~eson 999b) : · Generate the initial product realization document with emphasis on mechanical piece parts; Update the initial product realization document to include electrical piece parts; · Evaluate, procure, and integrate initial collaboration tools, including The Web Integration Manager (WIM)
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From page 59... ...
A WIM pulls together all functions, including product design, process planning, process simulation, and fabrication controls. These integrative elements are what make the Tl ME approach possible today.
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From page 60... ...
, the typical time for transitioning a new energetic material to production exceecis a clecade. The potential exists for TIME to reduce this time by half by integrating tightly coupled mathematically based modeling and simulation tools throughout the product realization process and by utilizing the TIME enterprise to remotely monitor and troubleshoot production processes.
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From page 61... ...
Robust tools can be used to develop new energetic compouncis, establish process parameters on different TSE equipment, ancl transfer processes from the development laboratory through scale-up to full procluction. In developing such models, the heavy computational requirements of the TSE finite element analysis programs should be carefuliv considered.
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From page 62... ...
The goals of the TIME product realization process for mechanical piece parts are presented below (Raytheon 1999~: Create an architecture sufficiently flexible to allow the integration of new technologies into the design process without interrupting other processes or resources within the enterprise or the product realization process. Establish a process that reduces time-to-market by decreasing rework, reducing the number of prototypes, introducing agile manufacturing techniques, and implementing modeling and simulation software tools.
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From page 63... ...
identifies the high-level requirements of the workflow modules for seamless integration of the product realization process of mechanical piece parts. The TIME concurrent product realization concept generally operates on the premise that once customer needs are established to the point that product requirements can be discretely defined, the producibility, process modeling, simulation, analysis, and resource planning functions should interoperate seamless~y and concurrently to provide accurate assessments of cost, performance, and schedule for conceptual product realization approaches.
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From page 64... ...
The output from optimizing the concepts of the product design is a refined set of prioritized requirements, sometimes referred to as a "baseline script," that feeds into the design optimization phase. Design Optimization The design optimization process is based on concurrent development and execution of the "procluct realization script." The script is optimized for performance and value by trading off critical parameters in the product, process, and resource domains.
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From page 65... ...
The output of the design optimization step, sometimes referred to as the "manufacturing script," incorporates the product design and information about design for manufacturing. The design optimization step for mechanical piece parts comprises CAD/CAM/CAE processes.
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From page 66... ...
Meeting the customer requirements for the new mechanical piece part is the ultimate measure of success for the product realization process. Conceptual Design Cockpit Integrated product realization, with its systematic approach to manufacturing, opens the door for knowledge-based systems and automated information generation.
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From page 67... ...
. (The acronym PDES is also used for Product Data Exchange 2 Although the committee strongly recommends that the munitions industry begin using integrated COTS CAD/CAM systems of the types presented in this list, the list is by no means complete and does not constitute an endorsement of any specific commercial system.
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From page 68... ...
Thus, TIME should focus a substantial portion of its CADrelated efforts on detailed definitions of user needs for design systems, monitoring the evolving graphics exchange standards, and ensuring that the munitions enterprise system will remain operational and as error free as possible, as the exchange standards, hardware, and software systems used by the various participants migrate. Recommenclation: The TIME program should focus a substantial portion of its CAD-related efforts on detailed definition of user needs for design systems and should not invest TIME funds in developing graphics exchange standards.
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From page 69... ...
of appropriate CAD/CAM systems and manufacturing environments for process planning and machine tool programming. TIME should also focus on issues of interactivity and interoperabi~ity between myriad CAD/CAM systems used in the munitions and dual-use industries and on ongoing commercial efforts to improve interoperability of COTS systems such as PDES/STEP, as well as their integration with the broader manufacturing environments for process planning and machine tool programming.
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From page 70... ...
Thus, as munitions concepts mature, information must be downloaded and re-entered into CAD/CAM before physical hardware can be produced. Although not currently a part of TIME program plans, this is but one example of the near-term opportunities to implement some of the key technologies outlined in the TIME enterprise architecture and to enable a substantial return to the taxpayer.
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From page 71... ...
Manufacturing is likely to become more computerized in the future, and generative process planning, in which information is passed directly between the product design computers and the manufacturing engineering computers, may be able to reduce the number of false starts of the manufacturing process and provide consistent methods to the shop floor. New machine programs will likely be produced by computers that utilize information passed to them by process planning software.
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From page 72... ...
In the longer term, TIME should investigate systems such as Windchill, Metaphase, and Matrix-1, as well as Internet-based products.5 Recommendation: The TIME program should investigate and implement COTS software packages that enable more effective communication among a variety of CAD and CAM systems. Rapicl Prototyping Since the introduction of practical rapid prototyping processes approximately 20 years ago, these technologies have become an important part of rapid, cost-effective product realization processes in many industries.
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From page 73... ...
In addition to the finite-element-analysis methods used in commercial design and manufacturing, expert systems (Barr and Feigenbaum 1981) are valuable for formulating solutions to manufacturing problems that cannot be solved using quantitative analysis.
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From page 74... ...
It is concurrently getting under way as part of the TIME program's efforts at Picatinny Arsenal, Stevens Institute of Technology, and Thiokol Corporation to model and electronically control advanced twin-screwextruder processes for processing energetics. These efforts are representative of the advancements required to modernize the munitions industry.
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