The document discusses how digitalized manufacturing can transform businesses by allowing companies to produce customized parts for next generation machinery through innovative technologies like additive manufacturing and robotics. It promotes the benefits of a model-driven process using a single system with consistent data to streamline workflows and drive entire operations. This approach aims to maximize production efficiency, harmonize part design and manufacturing, and ensure jobs are delivered as planned by uniting the virtual and physical aspects of production.
Welcome everyone. My name is _______ and I want to thank you for joining our webinar focused on the industrial machinery industry.
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For machinery manufacturers, success depends on their ability to address today’s challenges. Increased design complexity, need for customization products, and globalization are just some the challenges that impact them.
Today you will learn how you can digitalize your part manufacturing process to help you transform your entire business to be more competitive in today’s environment.
So let’s get started…
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We can all attest to the massive changes we see happening every day across the globe. The global population is growing at extraordinary levels. Along with this, there are clear differences in the wants and needs from consumers based on cultural, geographical and other characteristics. This is many times called the personalization of society. We see this clearly in something as simple as footwear.
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It doesn’t seem like very long ago, but a sneaker (also can be called “trainer”, “gym shoes”, “athletic shoes”, etc.) came in one style, and maybe it was available in 2 or 3 colors.
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Now, of course, one can custom order a sneaker with up to 20 different components and colors. And it’s not just footwear. It’s customized perfume bottles where each bottle coming across the machine conveyor belt can differ in size, style, and also include personalized engraving. In the food and beverage business, manufacturers that used to deliver a single type of food item are now manufacturing 20 plus different types of the same item depending on color, taste, and other consumer demands.
All this points to machinery manufacturers needing to clearly understand the markets for different products, different customer bases, new territories, and build machinery that will produce exactly what their customers, and ultimately consumers want.
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As mentioned in the previous slide, the world’s population continues to grow at increasing levels. This demand for personalized or customized products is now putting increased pressure on machinery manufacturers to meet these advanced requirements.
According to a recent Joint Research Council Foresight study from the European Commission, “customization and personalization will drive how industry operates”.
Millions of new consumers will demand customized and personalized goods to satisfy their needs. This will result in millions of new customers from regions requiring diverse features and pricing. While ultimately this is great news for manufacturers, it also speeds up the need for ever increasing complex machines that can handle this customer demand.
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Another trend in industrial machinery is that government and environmental regulations are growing.. This is a challenge as well as an opportunity. It means many machinery manufacturers must look for new products and solutions to meet the regulatory requirements. If their machines don’t meet new, stricter guidelines, they can’t deliver them to customers. If they can’t deliver them to customers, they become unprofitable. You can see how quickly the effect of not adhering to requirements can negatively affect one’s machinery business.
In this example, the data from NERA Economic Consulting is alarming. In the United States alone, new annual regulatory requirements have doubled over the past 10 years. Adhering to these new mandates creates a huge burden on product development processes and the machine builders that have to adhere to them.
The challenge is to find cost-effective approaches to meet the regulation-related requirements.
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In addition to customization and regulatory requirements, globalization also impacts the Industrial Machinery industry. The issue is best shown in that by 2020, 80% of the world’s manufacturers will have global operations, compared to just 50% today. In less than 4 years, every one of us will likely be facing new, and possibly more nimble, flexible and lower cost competitors.
The question each machinery manufacturer needs to ask is, How do I delivery more complex machinery, faster, at a competitive price, and stay profitable?” This is not an easy problem to answer.
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To effectively respond to today’s challenges, manufacturing is going through a technological renaissance that is digitally transforming the industry.. Digitalization provides ways for you to deliver powerful advantages, including:
Use new, revolutionary technologies, such as 3D printing to make a new class of products
Connect people, equipment and the entire process with a digital thread
Optimize manufacturing operation with a digital twin
Deliver high-quality parts to plan by uniting the virtual and physical worlds of production
Let’s look at the part manufacturing process.
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The manufacturing process starts with input from the part design data. Based on the part model, manufacturing engineering defines the plan that specifies what will be made, through what process, and with what resources and equipment. Here applications such CAM and CMM software are used to prepare programs to drive the equipment.
The success of part manufacturing is most obviously seen at the point of production. It’s on the shop floor where the practical details that have a critical effect on manufacturing efficiency become a reality.
We are going to show the value of digitalizing the entire part manufacturing process. We’ll look at how the digitalized production can help you address some of the critical challenges that manufacturers face…
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Customers expect you as a manufacturer to shorten your overall lead times and meet the delivery requirements.
However, two thirds of manufacturers struggle to achieve a satisfactory on-time delivery performance, according to a survey.
So, how can you reduce your lead time and improve your on-time delivery rate?
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You can start streamlining your workflow by using consistent and associative manufacturing data throughout the production process. This includes 3D models, setup assemblies, and NC programs. Change orders and late requests can be handled relatively quickly and easily when all of your work remains associative to the solid model.
Also, when all the stakeholders, teams and departments use a single software platform to drive the manufacturing process, they can collaborate easily and effectively. For example, it is much easier for the manufacturing team to drive design changes that improve manufacturabilty.
By driving your entire operation with a digital twin of the physical parts you are manufacturing, you can enhance your efficiency. We call this a model-driven process.
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It all starts with the drawing or the model of the machined part. Many machinery OEMs and their suppliers produce a wide range of machinery parts similar to this one...
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Now we’ll see how this digital twin of the physical part can drive the entire manufacturing process…
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The 3D solid part model can be read or designed in NX. This digital twin, which is an accurate representation of the part is the input to the manufacturing process.
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To define the machining process for this part, you can start by preparing the geometry for NC programming. Also, using NX CAD, you can quickly design associative fixtures. By using the digital twin of your machine setup, you can create and validate toolpaths using the advanced NC programming and simulation capabilities in NX CAM.
You can easily prepare a complete set of shop documentation, including CNC programs, tool lists, setup sheets, and drawings. This work package can be directly transferred to the machine tools on the shop floor.
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At the same time while you were defining the machining operations, the quality-inspection team can work on specifying the inspection process, working on the same data… and using the same integrated NX system. NX CMM lets you automatically create inspection paths using the PMI data (or Product and Manufacturing Information) that can be attached to the part model. The generated and verified inspection programs can be transferred to the production to drive the CMM equipment on the shop floor.
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The model driven process ensures efficient manufacturing cycle (from Preparation and Programming to Production), which can give you significant advantages, including
Associativity to the supplied design data,
Concurrent workflow, and
Accuracy and reliability
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The NX system provides a wide range of capabilities for NC programming, postprocessing and machine tool simulation.
From simple 2-axis milling to high-speed machining and multi-function 5-axis machines capabilities, you have the flexibility to program any job on any machine tool using a single CAM system.
To ensure high quality products, NX also provides an integrated solution for quality inspection…
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Coordinate measuring machines (CMM) are key quality control features of manufacturing shops. NX CMM inspection programming can efficiently program CMM equipment and also read the results back into NX for visual comparison and analysis.
You can automatically create complete inspection programs using the PMI (or Product Manufacturing Information) data that can be embedded into the digital twin of the part. Advanced inspection programming capabilities let you efficiently drive the latest equipment. For example, with the high-speed inspection methods that use “head touches”, you can collect measurements 3 times faster with improved accuracy and repeatability. Programming in the context of the CMM machine, ensures optimized and safe inspection paths. You can output validated and production-ready programs to drive CMM machines on the shop floor.
And after the inspection is performed, you can read measurements from the shop floor and overlay it on the digital model in NX for analysis.
This closed-loop solution helps you compare the as-designed and as-built results to understand if there is a difference, why it’s different, and what should be done to adjust the process.
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By using a digital twin of the parts, resources and the entire process, you can harmonize the entire production process - from planning to manufacturing execution, which can reduce your lead time and improve on-time delivery rate.
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Production throughput depends on the efficiency of the entire part manufacturing process. Inefficient machining, machine downtime, and errors on the shop floor can have cumulative effect on your overall throughput.
To improve throughput and be more competitive, manufacturers need to maximize use of resources and reduce the cycle time. Using the latest programming and machining methods and introducing of new, innovative technologies, such as 3D printing can help manufacturers achieve a new level of efficiency.
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You can increase your machining efficiency and reduce the cycle time by automating the NC programing to create optimized machining processes.
You can automate the NC programming process by using feature-based machining. NX can automatically recognize machining features and create complete machining processes. This capability is ideal for programming machinery components that can have many features, such as pockets, slots and complex holes that would require a lot of time to program using traditional methods. With feature-based machining, you can reduce programming time by as much as 90%.
With NX, you don’t need to start every job from scratch. For instance, machining data library and process templates enable you to re-use proven data and processes. This knowledge-driven programming can improve your productivity and ensures repeatability.
The intelligent tool paths generated by NX CAM ensure efficient machining and increased machine tool performance. Let’s take a closer look at some of these advanced NC programming capabilities for programming and machining cutting prismatic parts, such as components used in the machinery industry.
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NX CAM can help you accelerate the programming of prismatic parts that can have simple shapes, but may require complex machining process. And the optimized tool paths can minimize the cycle time on the machine tool.
For example, with volume based milling you can quickly program prismatic parts by specifying the volumes to be machined on the 3D solid model. In the process, NX presents you with the current in-process workpiece (IPW) and displays the calculated cut levels and the updated IPW. This automated process is much faster and more reliable than using traditional programming methods that require manual creation and selection of manually-created boundaries.
To program tombstone and fixture configuration, you can use multiple parts programming function. It enables you to program a single part and then copy the tool paths to all workpieces in the assembly. The created operations are associative, which enables you to easily make tool paths adjustments that automatically propagate to all the parts.
The latest multi-function machine tools, which are capable of both turning and milling, minimize the number of setups required to machine a part, which can significantly improve your shop-floor productivity. You can efficiently drive the latest multi-function machines with NX CAM that offers a complete range of capabilities, from turning to simultaneous 5-axis milling. The interactive and visual tools allow you to easily synchronize and optimize the machining sequence.
To avoid errors on the shop floor, you can accurately validate your operations by using a digital twin of your entire machine setup. NX CAM provides integrated simulation and verification, which can be driven from the NC output of the postprocessor. As G-codes are processed, the digital twin of the machine – with the part, fixtures and tooling – moves in the way the real machine tool will move.
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Telsmith is a manufacturer of large-size equipment for aggregate processing, including rock crushers. With NX CAM, they can generate more programs in spite of driving more complex machines. They rely on the high-speed machining capabilities in NX CAM to reduce machining cycle.
By using Siemens’ software and controllers, Telsmith increases the CNC programming output and maximized the machine tool productivity, which helps them increase their overall throughput.
Many machine shops embrace new, innovative technologies to gain a competitive edge.
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For example, the use of robots for machining on the shop floor is expanding rapidly.
Beyond the familiar tasks of lifting, positioning and welding, robots are being fitted with tool holding heads, so you can perform machining operations…
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Some of these machining operations include deburring, grinding, cutting, trimming, polishing, and finishing.
You can improve your productivity by taking advantage of these continuous technology advances. The robotic machining lets you increase your flexibility to machine larger parts in a single setup and improve repeatability and accuracy by relying on the robots’ precision motions.
Siemens PLM Software has integrated its proven robotic Tecnomatix technology with the advanced CNC programming capabilities of NX CAM to provide a complete solution for Robotic Machining. Leveraging this sophisticated technology, you can automate complete manufacturing processes on the shop floor. The reduced machining cycles, and improved quality can help you increase your overall production efficiency.
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Additive manufacturing, also known as 3D printing, is a transformative technology that build parts by adding material, rather than subtracting like the conventional machining.
Manufacturers—from small job shops to large multinational companies - transition from prototyping to the production of final products.
It’s been rapidly adopted by many industries, because it frees manufacturers from the limitations of conventional machining. Additive manufacturing enables production of parts that you couldn’t make before. Increased use of new materials, including various metals only accelerates the adoption of this technology. For some parts, such as castings, the production cycle can be reduced from several months to a couple of weeks.
According to a survey of US manufacturers, 75% of companies are already adopting 3D printing in some way—from experimenting with the technology to making final products.
To expand the applications of additive manufacturing to produce production-quality metal products, a new technology was recently introduced…
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Hybrid manufacturing combines additive manufacturing and CNC machining into a single machine tool environment.
By building up complex geometries using the additive process, including internal cavities, then machining them for tight tolerances as they are built using CNC machining, you can manufacture new classes of parts or consolidate many setups into one.
NX is leading the industry with support for the new hybrid additive manufacturing technologies as shown in the next short demonstration…
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[below is the script for the demo video that is 1:17 minutes long]
NX CAM provides a complete solution to drive the latest hybrid additive machine tools built by DMG MORI.
With the new capabilities, you can quickly create additive operations with NX CAM.
The integrated verification lets you validate the laser metal deposition process as you program. It ensures an efficient process on the shop floor.
You can accurately simulate 5-axis additive operations by using the digital twin of the machine tool, which can minimize the setup time on the shop floor.
This new technology lets you switch between 3D printing and CNC machining, allowing you to make parts that you couldn’t make before.
You can machine smooth surface finishes by using the advanced NC programming capabilities in NX CAM.
By alternating between additive and CNC machining, you can manufacture complete parts in one setup.
The combination of the two technologies in a single environment, lets you produce high-quality, production-ready parts on a single machine.
The innovative hybrid additive technology is transforming the manufacturing process.
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By using new, advanced technologies you can maximize your production efficiency and improve your manufacturing throughput.
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Often, manufacturers rely on a disconnected workflow with pockets of valuable information and know-how residing across the company in different systems.
The flow of manufacturing information between people, departments, and technology might involve paper trails and manual processes. It should be no surprise that this kind of information flow challenge can impact production targets.
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Let’s look at how you can unify and streamline the information flow to eliminate delays and ensure that the right people have access to the right manufacturing data.
By organizing the manufacturing information in a single source of data you can reuse the company know-how and best practices.
The disconnected process can be particularly obvious when connecting engineering and the shop floor. We’ll show you how you can deliver the correct manufacturing data to production
So let’s see how you can digitalize the entire part manufacturing process…
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The CAD-CAM-CNC process chain supports the core machining solution, which meets the requirements of many manufacturers. However, there are also companies that need additional applications and equipment to complete their part manufacturing process.
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For improved collaboration, Siemens provides Teamcenter for data and process management. It enables the manufacturing team to work together using a single source of information.
Connecting NX CAD, CAM, and CMM to Teamcenter establishes a basis for an extended part manufacturing solution. All types of manufacturing data, from 3D part models to setup sheets, tool lists and CNC programs can be fully managed.
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To define the process sequence for manufacturing parts, you can use Part Planner, a Teamcenter application. It lets you standardize the process and re-use proven processes.
The Manufacturing Resource Library, gives you a central access point to cutting tools, fixtures and other resources for your entire company. Tooling data, based on standardized tool vendors’ catalogs can be assembled and organized for your specific manufacturing operation. The integrated solution lets you access classified cutting tools from NX CAM, so you can easily find the right tool for the machining process.
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All the production data (such as process plans, CNC programs, tool lists, setup sheets, and inspection programs) generated by the digital manufacturing software and managed in Teamcenter now needs to be transferred to the shop floor.
In many cases this is done inefficiently by taking paper drawings, memory sticks and spreadsheet printouts to the point of production.
Siemens provides an efficient way to bridge the gap between engineering and production…
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By extending PLM to the shop floor you can deliver manufacturing data from Teamcenter directly to the shop floor, with no local data storage, thus eliminating duplicate data.
The production staff can access current and released CNC programs, drawings, 3D models and other data managed in Teamcenter making sure that the correct manufacturing data is used in production.
Also, shop floor applications can be connected to Teamcenter. For example, tool data management lets you ensure that tools are properly prepared and available for scheduled jobs.
The machine-specific CNC programs can be delivered directly to machine tools. And to ensure high-quality parts, you can drive the inspection machines using the CMM inspection execution application.
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This diagram represents a view of our complete solution for digitalized part manufacturing - from planning to production.
Let’s now see the solution in action…
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[below is the script for the demo video that is 4:05 minutes long]
With NX CAM for machinery, you get a full range of NC programming capabilities to efficiently manufacture machinery parts.
Program your prismatic parts twice as fast with volume-based milling. Select floors and walls and then let NX CAM calculate the machining volume to create smart tool paths. Because NX tracks and displays the remaining material after each operation, you can easily create tool paths that efficiently cut leftover volumes.
NX provides a simple way to program parts that require multiple setups. It automatically tracks the in-process workpiece across the entire process so that repositioning moves are kept safe, machining operations optimized, and air cuts minimized.
And with NX, you only need one system to drive milling, drilling, turning, mill-turn, and Wire EDM machines. The tracking of the in-process work piece makes programming fast and simple – even when the part is transferred from machine-to-machine.
Manufacturing Resource Library (or MRL) is a Teamcenter application that lets you manage all of your manufacturing resources. With MRL you can assemble your cutting tools using the components stored in a fully classified library. MRL can be accessed directly from NX CAM, so you can search and retrieve the tools needed for NC programming.
You can automate programming for standard features, part families, and even multiple parts arranged in fixtures. Program a single part and copy it to all the workpieces. The collision-free toolpaths are associative, which lets you adjust a single operation and the system will automatically update all the toolpaths.
There’s no need for extra 3rd party machine tool simulation software to check tool paths. You can validate your programs directly inside NX CAM. Use integrated g-code driven simulation to accurately represent how your machine will actually perform on the shop floor. A 3D model of the machine – with the part, fixtures and tooling – moves according to the postprocessed NC program.
The integrated CAD capabilities let you design fixtures and clamping devices. The knowledge re-use library enables you to easily access your standard parts for setups. By using the assembly capabilities you can quickly position parts in context.
The setup configurations can be easily shared with the shop floor, via conventional drawings or 3D viewer technology.
NX CAM automatically produces shop documentation that includes both tooling information and operation sheets that you can easily configure.
You can manage all of your manufacturing data, including 3D part models, resources, and NC programs in Teamcenter. This enables the entire team, including the production staff works to use the same source of data.
Using Shop Floor Connect, you can access, and review the revision-controlled manufacturing data in Teamcenter. The correct work package can be sent to production ensuring that the right data is used to machine parts on the shop floor.
By digitalizing your manufacturing process, you can unite the virtual and physical worlds of production. The established digital thread that connects people, equipment and the entire process helps you optimize the operations to deliver high-quality parts.
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By seamlessly uniting key elements from design, through manufacturing, into a virtual model that performs like the physical equivalent you can implement a complete part manufacturing solution with efficient information flow throughout the process.
All of this enables you to deliver the products your customers want, grow profits, and gain efficiency.
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Fooke develops, manufactures and installs large portal milling machines with drive mechanisms and clamping solutions.
To streamline development of these complex machines, Fooke leverages the end-to-end manufacturing solution from Siemens.
Having integrated CAD and CAM systems save the company hours of data conversion. And having a common information platform – Teamcenter – improves the cooperation among the different divisions.
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You can digitally transform your production and become more competitive, efficient and profitable. Digital manufacturing provides unique and powerful advantages:
Harmonize part design and production with a digital twin
Maximize production capacity by using new, revolutionary technologies
Deliver jobs to plan by uniting the virtual and physical worlds of production
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To learn more, please join the discussion on our public manufacturing forum, where you can learn from experts and stay informed about the latest news.
Our website provides detailed information about our solutions, including videos and case studies. To explore the world of digital manufacturing on your tablet, you can download the Manufacturing 360 app from the Apple and Google app stores.
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Thank you for your time.
Please contact us if you need more information.
