Modeling and Simulation in Manufacturing and Defense Acquisition Pathways to Success (2002) / Chapter Skim
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3 Lessons Learned from Commercial Manufacturing
3 Lessons Learned from Commercial Manufacturing
Pages 47-62
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From page 47... ...
The committee first examined the current uses of M&S technologies in commercial manufacturing, using the automotive industry as an example, and identified barriers to more widespread use. The committee then analyzed the work of the Integrated Manufacturing Technology Initiative (IMTI)
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From page 48... ...
The company credits rapid prototyping tools with permitting the creation of physical models to verify designs, and it credits computer engineering tools with permitting rapid modification of designs as problems were found. The engine was not derived from previous designs (Vasilash, 1998~.
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From page 49... ...
These barriers include the lack of reusability of existing successful applications, the lack of model reliability and robustness, limitations on integration of systems, and barriers caused by management and process structures. Lack of Reusability Most successful M&S applications have been solutions to specific problems at the level of a single project or a single part.
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From page 50... ...
and flight simulation, again with essentially no connection to the three-dimensional solid modeling. Thus while each of these separate modeling efforts benefited from the separate CAD tools available in their specialized domains, this is far from the highly integrated VE environment that is envisioned for the future, and is indeed far from even some of the popular images of the current practice.
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From page 51... ...
Only M&S can shed light on this process, but exploration of system behavior through simulation response to random inputs is time-consuming. Existing Management and Process Structures Existing management and process structures are outdated and therefore represent barriers to the widespread use of M&S technologies in manufacturing.
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From page 52... ...
In this context, "integrated manufacturing" was defined as the effective integration of production, design, supply, and marketing functions to enable improved control, management, and planning for the enterprise. The R&D agenda that was developed addressed key technology goals cutting across all manufacturing sectors and recognized M&S as a critical enabler to support future manufacturing.
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From page 53... ...
As indicated in Table 3-1, the IMTI vision for a future ideal state of M&S use in product design applications includes models that capture all product attributes; interoperability between product and performance models; more accurate cost estimating; manufacturing process requirements included in an integrated design system; all life-cycle considerations included in the product model; and a situation in which analysis leads design, rather than supporting it. Limitations on this vision include those on bandwidth, computation speed, memory, and other communication and computation resources.
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From page 54... ...
Real-world limitations to the achievement of the ideal state shown in Table 3-2 include limitations on model content and available knowledge. R&D required to reach this state includes continuity of modeling information across life-cycle phases, standards for product models, improved interoperability, improved composability, use of families of multi-resolution models, integrated verification and validation, placing M&S tools and systems under knowledge-based control, and a universal framework for model construction.
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From page 60... ...
Increased capabilities to reuse successful product design applications for other problems or to integrate successful product design applications into larger systems; product model standards modularity of M&S components, and improved comparability; Improved integration of models; improved CAD software that enables use of product models in performance simulations of dynamic-use conditions; improved interoperability; Improved model validation and verification methods to increase reliability and robustness to uncertainty of product models; integrated verification and validation of models and simulations; Improved parametric modeling, variational analysis, and probabilistic design to increase use of M&S analysis in design process; Universal framework for model construction that incorporates both stochastic and deterministic models to optimize manufacturing parameters. The committee identified needs for improvement in M&S technologies for process applications, including the following: Improved capabilities for integrating systems, such as improved methods for understanding systems behavior and improved integration of performance modeling and effectiveness simulations with product modeling and engineering simulations; .
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From page 61... ...
M&S IN COMMERCIAL MANUFACTURING TABLE 3-3 M&S Needs for Commercial Manufacturing 61 Category of Need . Product and manufacturing Specific Needs process design Process applications Product development process Increased reuse capabilities Improved integration of models Improved model validation and verification Improved design modeling methods Universal framework for model construction Improved system integration Continuity of models across life cycle Improved heuristic search methods Improved testing and evaluation Encourage use of M&S in product design, testing, and evaluation Finally, the committee identified the need for nontechnical improvements in the product development process to encourage, rather than discourage, full use of M&S analysis capabilities in design and full use of M&S capabilities in product testing and evaluation (see Table 3-3~.
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