DPE Training Doc

Introduction:In this project you will learn the basic structure of Process Engineer. By the end of this training you will be able to:∙ Structure information, build nodes, and input data that will reflect the intention of the process.∙ Edit and rearrange both the graphical and textual data and see those changes reflected in the database as viewable and appropriately represented in the different nodes of the project.∙ See the CAD data accessed and reflected inside the Process Engineer software, illustrating the power of the Dassault Systemes / DELMIA Product Lifecycle Management solution.Scope:This exercise will go over launching Process Engineer and going over some basics of the process engineer user interface. This step will also go over creating a New Project, which will be used all through this manual.Procedure:1. Launch Process Engineer by selecting Start | Programs | Delmia | Process Engineer.Launch Process EngineerFacilitated Project: “Briggs & Stratton Engine”2. The following Login screen appears. Enter the following information and click on OK. Login : adminPassword : admin3. The following figure shows the user interface of process engineer.4. Once you have launched Process Engineer you will see the screen which looks similar to the above screen. You may have an existing project open. If that is the case please close the project by selecting File | Close.Menu BarMain Tool BarContextual Menu ObjectsPPR Navigator Browser WindowTabObject PropertiesMessage WindowWorkbench5. You will have a screen, which looks like this.6. Create a new project by selecting File | New Project7. From the Plantypesets Dialog b ox select “Demo PTS English” as the Plant Type Set and click on OK8. The Project <New Project> window appears. Enter the Project Name as “3.5 HP Engine” and click on OK.9. The New Project is created. Open the project structure by double clicking the various nodes. It will look like the following.Introduction:In this project you will learn the basic structure of Process Engineer. By the end of this training you will be able to:∙ Structure information, build nodes, and input data that will reflect the intention of the process.∙ Edit and rearrange both the graphical and textual data and see those changes reflected in the database as viewable and appropriately represented in the different nodes of the project.∙ See the CAD data accessed and reflected inside the Process Engineer software, illustrating the power of the Dassault Systemes / DELMIA Product Lifecycle Management solution.Scope:This exercise will go over definition of Premises in Process Engineer and also will create some typical premises for the Briggs and Stratton 3.5 HP Engine.Definition:Premises are all boundary conditions affecting the workflow and the results of productionplanning. Typical premises are Shift Plans, Wage Groups, Target Numbers, PoT (Pieces Over Time), etc.Customer’s Premises:After a start period with 50,000 ordered engines the production figure rises to 110,000 engines per year. The start date of this yearly requirement is 01.06.2002 (dd.mm.yyyy) After 01.06.2003 the quantity of units increase to 250,000 engines per year. This rise of yearly requirement in the second and third year will be realized by introducing a second working shift.Calculation of cycle timeFrom 01.03.2002 until 31.05.2002: 1 working shift: 50,000 engines From 01.06.2002 until 31.05.2003: 1 working shift: 110,000 engines From 01.06.2003 until 31.05.2005: 2 working shifts: 250,000 enginesDefine PremiseFacilitated Project: “3.5 HP Engine”Estimation of target cycle timerpieces/yea 110,000min/shift480x days/year working 220 0.96 minNote : To create the shift model, PoT curve and wage groups assume that today’s date is 01.03.2002.Procedure:With the “3.5 HP Engine Project” already created, this step will go over creating some premises which will be used in the following modules to do some analysis.Define Shift Model1) From the Project Library node select Shift Model and right click on it to bring up the contextual menu and select New | Shift Model.2) Define the name of the shift model as “Standard Shift”. Clicking OK will create the Shift Model3) To input more information the Extended Properties for this shift model will be used. Select the shift model just created from the PPR Navigator Browser window and right click to select “Extended Properties” from the contextual menu.This will bring up the Extended Properties for the shift model just created.Enter the following properties for the Standard Shift.Standard Shift 220 Working Days/Year 480 min/shiftThis is entered in the Extended Properties dialog box by selecting “New” button and then editing the fields by double clicking on them.4) Repeat steps 2 and 3 to create another shift model called “Double Shift” asDouble Shift 220 Working Days/Year 480 min/shift 480 mins/shiftThe Extended properties for the “Double Shift” will look like this:Define PoT (Pieces Over Time) Curve5) From the Project Library expandthe PoT Curves selection. From the expanded folders select “Base PoT Curve”. Right click to show the contextual menu and select “NewBase PoT Curve”.6) Name the PoT curve “3.5 HP Engine POT” and click OK7) Now, right click and Select the “Extended Properties” from the contextual menu of the newly created POT curve.Use the “New” button to define the Beg in dates and PoT as followsFrom 01.03.2002 50,000 engines/piecesFrom 01.06.2002 110,000 engines/piecesFrom 01.06.2003 250,000 engines/piecesUntil 01.06.2005 0 engines/piecesThe PoT curve created will look like this. Leave the Machine and Worker availability to the default values of 100%.Define Wage GroupsTo create a new wage group from the projectlibrary select the contextual menu for WageGroup as shown.Name the wage group “Standard Wage Group” and choose the wage c ost as $40,000.00.To change the currency units right click in the wage cost field, and select the currency type from the drop down list.Scope:In this step we will go over creating a simple product structure (Design Bill of materials, DBOM and Manufacturing Bill of Materials, MBOM). The DBOM will be created using the interactive contextual menu option on the main project Node “3.5 HP Engine”. In this step the DBOM will also be created using the PPR loader from the existing config files and the data source file. The second procedure will show the creation of the MBOM using references to the design view products. Finally, we will talk about filters, calculation models and SA codes.Procedure 1:Creating the DBOM (Design Bill of Materials):1. With the existing project (3.5 HP Engine) open, create a “New” - “Product View”using the contextual menu at the main project node.Product PlanningFacilitated Project: “Briggs & Stratton Engine”2. Name this product view “Product View” and click on OK. You will notice that t he ProductView shows up in the project tree.3. Select the Product View from the project and using a right click to bring up the contextualmenu, create a “New” –“ Design View”.Name the design view “Design BOM”and click OK to establish this node.4. Open the newly created Design BOM node in the project tree and right click to obtain thecontextual menu. Select “New “| “Subassembly”.Name it “3.5 HP Engine” and click on OK.5. Now we can go ahead and create the parts in the product structure. We will do this twodifferent ways. First , manually, then by using the PPR Loader.IMPORTANT NOTE: In practical application additional subassemblies would be created under the 3.5 HP Engine. Each of these subassemblies would then have their individual parts attached.However, in the interest of time, we are going to treat the following list of sub-elements of this engine as parts.First we will add parts manually. From the contextual menu of the 3.5 HP Engine subassembly just created select“New “| “Part”“Air_Filter”.7. Practice adding a few of thefollowing parts by repeating step5. This is just to show you themanual way of adding parts tothe product structure. In the nextfew steps we will use the PPRLoader method of bringing in allthis information from a plainASCII file.Block_AssemblyCam_AssemblyCarburetor_AssemblyCoil_AssemblyCover_AssemblyCrankcase_Cover_AssemblyCrankshaft_AssemblyExhaust_Valve_AssemblyFlywheel_AssemblyHead_AssemblyIntake_Valve_AssemblyMuffler_AssemblyPiston_AssemblyPiston_Rod_Assembly8. After having seen the method in which we cancreate the parts manually we will delete theproduct structure just created so that we canuse the PPR Loader to bring in these parts.To delete the just created Design BOM, select the 3.5HPEngine contextual menu with a right click and select“Delete”.9. Select “Deep” to delete the link, component, and its children10. Now we will use the PPR Loader method.We will use the following existing files..\PPRClient\data\product_cadpath\Engine_import_English\Product_with_cadfile.dat ..\\PPRClient\data\product_cadpath\Engine_import_English\Product.cfgNOTE: To create the Product structure from scratch. The .dat file could have come in as an output from the installed PDM system within the organization.11. Launch the PPR loader in Process Engineer12. When the PPR Loader window appears, select the data source file(..\PPRClient\data\product_cadpath\Engine_import_English\Product_with_cadfile.dat).13. You can use the browse button to findthe files, if necessary.14. Select the Config button to set the config file(..\\PPRClient\data\product_cadpath\Engine_import_English\Product.cfg).Notice the Use Configuration file radio button and then click OK15. When theconfig fileselection iscompleted,you willreturn to theoriginalwindow.In theProject/Productsection, select“3.5 HP Engine /New Product”from the dropdown menu.This will createthe new productin the existing16. After having made all the selections, click on the Load/Sync button.17. After the PPR loader action is complete, save the currentproject by selecting File | Save All.18. Close the existing project by selecting File | Close.19. Now, Reopen the “3.5 HP Engine” project by selecting File | Open Project.20. Go to the Project Library node and expand it by clicking on the + . You will see a foldercalled “Product Components”.21. Expand the sub folder called “Design View”22. Then expand the folder called “New Product, 1”. You will see the 3.5 HP Engine,andwhen you click on that you will see all the components that have been imported from the PPR Loader.23. Select the “3.5 HP Engine” subassembly from “New Product,1” and drag it to the“Design BOM” node in the Product View.24. The message will appear askingconfirmation for the link operation. Click OK.10. The completed DBOM for the engine will look like following.11. The data source, which was brought in using the PPR loader, has the CAD data alsospecified for the parts of this engine. This geometry exists in the CGR format and has been placed in the correct location for Process Engineer to access.TRY IT: Select Block_Assembly from the DBOM. Bring up the contextual menu, and then select “Show Graphic”. This will bring up the 3D view of the geometry. Using the LMB and the MMB you can rotate and pan the geometry respectively.Procedure 2:Creating the MBOM (Manufacturing Bill of Materials):In this section we will use the DBOM components and create an MBOM from it.1. From the contextual menu of the Product view select “New | Production” view and nameit “Manufacturing BOM”.2. You will notice that the Manufacturing BOM node now appears in the product structure.3. From the contextual menu of the “Manufacturing BOM” add a new subassembly andname it “3.5 HP Engine Packaged”.4. Continuing as in the step above, add a subassembly named “Engine Complete” to the“3.5 HP Engine Packaged” node.Also, drag and drop “Assembly Instructions” and “Cardboard Box” from the DBOM over to “3.5 HP Engine Packaged” node.When prompted to create a link, click on OK.After this step the MBOM should look like this.5. Repeat the steps 1, 2 and 3 above to complete the creation of the MBOM.You will create a sub assembly under Engine Complete that is named “EnginePreassembly”. The Engine Complete node also contains the “Cover_Assembly “and the “Crankcase_Cover_ Assembly”. Drag and drop these parts from the DBOM to the Engine Complete node.Under the Engine Preassembly node, create another subassembly called “Piston Cylinder Assembly” , also addAir_Filter_AssemblyCarburetor_AssemblyCoil _AssemblyFlywheel_AssemblyHead_AssemblyMuffler_AssemblyUnder the Piston Cylinder Assembly node drag and drop;Block_AssemblyCam_AssemblyCrankshaft_AssemblyExhaust_Valve_AssemblyIntake_Valve_AssemblyPiston_AssemblyPiston_Rod_Assembly6. The final MBOM should look like the following.We have completed the DBOM and the MBOM which has given us a product structure. Now that the product planning is complete, the next step will be to plan the Process.Scope:In this section we will create two plans, a simple process plan and a production plan. The Processes are all actions or tasks performed to manufacture or assemble a product orsubassembly of a complete product. Name, number and process time specifically define the processes.In the process plan we will create a process graph and establish relationships between the products and the processes.In the production plan we will create production cycles, assign the processes to those cycles, and estimate then calculate their times.Procedure:Creating the Process Plan:1. With the existing project (3.5 HP Engine) open, create a new Process View using thecontextual menu at the main project node.Process PlanningFacilitated Project: “Briggs & Stratton Engine”When the Process View window appears name the new process vie w “Process View” and click on OK.View. Use the contextual menu(right click) to create a “New”“Process Plan”.Name the process plan“Process Plan 3.5 HP Engine”.3. Create a workplanunder the newlycreated ProcessPlan.Using the contextual menu,select “New” “Workplan”4. Name the workplan “Cumulative workplan”.5. In this step the operations need to be added to the workplan just created. Theoperations in PE can be added in the Project or in the Project Library or in the Process Graph.The operations can be added using the workplan’s contextual menu and selecting New | Operation.6. For the sake of this exercise, we will create all the operations in the Process Graph.Launch the Cumulative workplan in its own process context window as follows.7. Select “Yes” when you see the prompt to save changes8. Once the workplan opens in its own window, select the workplan and from its contextualmenu select t he “Open Process Graph”This will launch an empty process graph window. Shortly, we will add a number of Processes, name them, assign times and establish a priority order to the operations.But first, some basic maneuvers using the graph.using the Operation add button.Graph manipulation #2 Select the location in the process graph window where you wish to add the operation, click on the Operation button and then click on the graph in the area where you wish to place an operation. The “add operation” function is active if a parachute represents your mouse pointer. It will remain active, so you don’t need to select the operation button each time.Graph manipulation #3 Once you have put an operation on the graph, you can open the contextual menu of that operation bydouble clicking the operations symbol.Graph manipulation #4 The tabs on thedialog box that opens will allow you toinput the name of the operation and theprocessing time.Graph manipulation #5 You can define priorities in the graph by linking the processes with each other. Click on the junction point of one process and drag to the junction point of another process. The linking function is active if your mouse pointer is represented by a pencil.The lines will be either angular or horizontal depending on which line icon you select from the toolbar.Graph manipulation #6 You can zoom in or out on the graph by selecting the maginifying glass and then clicking on the graph area.Graph manipulation #7 Use the white oval to release the previously chosen function Graph manipulation #8 You can recover from a misplaced operation or connection by right clicking on the object and selecting “delete”.Back to the project9. Now place the 19 operations on the graph and reference the chart below to establish thenames and times for these operations.Operation TimeBlock AssemblyCam Assembly Crankshaft Assembly Exhaust Valve Assembly Intake Valve Assembly Piston AssemblyPiston Rod AssemblyAir Filter Assembly Carburetor AssemblyCoil AssemblyFlywheel AssemblyHead AssemblyMuffler AssemblyCover Assembly Crankcase Cover Assembly Piston Cylinder Assembly Engine PreAssemblyFinal AssemblyPackage 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.0 min 1.50 min1.60 min2.00 min10. Assign the priorities by linking the operations according to the completed graph below.Note : Processes created in the process graph are simultaneously entered in the PPR Browser structure.To edit the properties of an operation reopen the properties dialog from the PPR Navigator or from the process graph.11. Once your process graph looks like this, save all and close this view. Then close theCumulative Workplan view.12. You will be back at the main project window that shows the PPR Navigator. If youexpand the Cumulative workplan node you will see the processes that have just been input using the process graph.13. Once the process graph has been created and the times for the various operationsdefined, we can now define the relationships between these various operations.The following table describes the various product and process relationships. Note that some operations have 2 relationships. This will be important later.14. Referencing the above table, drag and drop the products from the MBOM to the variousoperations in the workplan. This will create the relationships.When dragging the product from the DBOM or MBOM onto the operation select OK on the “execute link” dialog box15. Referring to the table again, Notice that for the items: Piston Cylinder Assembly, EnginePreassembly, Final Assembly and Package -- two relationships must be established.Example: The Operation “Piston Cylinder Assembly will Create the Product called Piston Cylinder Assembly as it “Processes the Products, Block Assembly, Cam Assembly, etc. Be sure to establish each link. If you need to recover, click the right mouse button and select Delete, and when the prompt appears select Link only.“Process createsproduct” option refersto the fact that thisoperation creates theproduct.“Process processesproduct” refers to thefact that this operationprocesses the productand passes onto thenext operation.Notice that as the links are made, a new tab appears on the right side of the screen” Product is created by Process”. ( Remember that we treated the individual assemblies as parts for thistraining documentation) Although this screen shot shows the selected item to be under the DBOM, the process hand shows that the relationship has been established.The same applies to the Process View. If you select an item under the Cumulative workplan, you will see the tab “Process creates product” and the product icon.Now we will constrain the process even further. When you developed the Process Graph, you established a relationship between the various Parts and a Sub assembly. Now we will enforce that relationship by executing a sequencing constraint between the variousprocesses.16. Staying within the Process view, Drag and drop the Block Assembly process onto thePiston Cylinder Assembly process. Select “Must Succeed” since the Block Assembly must be done in order for the Piston Cylinder Assembly to be complete.17. Continue establishing a “Must Succeed” relationship between the following processes.a. The Piston Cylinder Assembly process must succeedi. Block Assembly processii. Cam Assembly processiii. Crankshaft Assembly processiv. Exhaust Valve Assembly processv. Intake Valve Assembly processvi. Piston Assembly processvii. Piston Rod Assembly processb. The Engine PreAssembly process must succeedi. Piston Cylinder Assembly processii. Carburetor Assembly processiii. Air Filter Assembly processiv. Coil Assembly processv. Flywheel Assembly processvi. Head Assembly processvii. Muffler Assembly processc. The Final Assembly process must succeedi. 3.5 HP Engine Preassembly processii. Cover Assembly processiii. Crankcase Cover Assembly processd. The Package process must succeedi. Final Assembly processii. The items Cardboard box and Assembly instructions are products under the MBOM and not processes.You have now successfully completed a process plan for the engine so, “Save All”Creating the Production Plan:Now once the various operations/processes have been created and assigned to theprocess/workplan how these operations will be divided among various cycles happening on various workstations needs to be decided.For this exercise we will manually (drag and drop) assign various operations to 4 different cycles. Initially, each cycle will parallel our process plan. For maximum throughput we will estimate each cycle to have a cycle time of 5.00 min. We will then compare our estimated cycle times to the calculated time.1. Create a new production plan by selecting “New | Production Plan” from the contextualmenu of the “Process View.。