Using Digital Twins for Modernizing Production Systems.pptx
- 1. 1 Copyright 2023 Prestin Group LLC Modernizing A&D Production Systems Graph Based Solutions and Breakthrough Improvement Authored by: David Prestin 2022 Dependency Structure Modeling Annual Conference in Eindhoven, Netherlands
- 2. 2 Copyright 2023 Prestin Group LLC What You’ll Hear Why Aerospace and Defense is so complex A Tale of Two Worlds – Analogue Manufacturing and Digital Manufacturing How Graph Based Solutions: DSMs, Network Insights, and Intelligent Scheduling help
- 3. 3 Copyright 2023 Prestin Group LLC Disclaimers The following stories are entirely fictional and any resemblance to an existing situation is purely coincidental The situations depicted here are on the extremes but we’ve experienced some flavor of what each describe The situations and personas depicted are for illustrative purposes only
- 4. 4 Copyright 2023 Prestin Group LLC Number of Parallel Paths Number of Dependencies per Task Hamburger Networks • Thick with lots of ingredients • Many integration/touch points • Messy and Complicated • Lots of variations • Graph based solutions necessary to simplify this complexity BEFORE other solutions applied Hotdog Networks • Long and narrow • Fewer parallel paths • Straight forward and orderly • Relatively few integration/interdependencies • Lean, Six Sigma, and “Best Practice” methods work wonders Why is A&D so Complex? Time, Space, and Scale!!!
- 5. 5 Copyright 2023 Prestin Group LLC A Tale of Two Worlds Analogue Manufacturing Digital Manufacturing
- 6. 6 Copyright 2023 Prestin Group LLC What is Business as Usual for Stan at Analogue Manufacturing? What’s his day like? VUCA Reigns Volatile: every day is a fire fight Uncertain: not sure which fire to put out first, second, third… Complex: lots of undocumented interdependencies across process, product, people, place Ambiguous: difficult to track down root causes and they seem to always change Why is it this way? Trapped: legacy factory layouts and monolithic processes/tools/mindsets Simplistic: methods and mindsets stuck in what only works in a much more orderly world Disempowered: digitized processes of old methods and mindsets resulting in more to answer to and not enough answers to prevent and manage disruption Disconnected: people, processes, product, and technology not designed and managed holistically Doing the same thing over and over again expecting different results
- 7. 7 Copyright 2023 Prestin Group LLC What is Business as Usual for Heather at Digital Manufacturing? What’s her day like? Slaying VUCA Dragons Variable: impacts are smaller scale and more easily managed Reliable: she and her peers know what’s expected, when, by whom and it’s repeatable Frictionless: she can quickly navigate to what’s relevant to her and upstream/downstream Transparent: less guess work in her day and relationships are clear to everyone Why is it this way? Digital Models: enable rapid reprioritization Buffers: strategic margins of safety limit ripple effects of disruption Simplified: Complexity is reduced as far as possible during the production design stage Connected: Process, product, people are connected via graph-based technologies so system states are clear and communication happens fluidly Planning Network Configurable Schedules Resourcing and Priorities Partitioned DSM w/ Historical Data Partitioned Arc Diagram
- 8. 8 Copyright 2023 Prestin Group LLC Digital Manufacturing Powered by Graph Based Solutions DSM’s and Network Insights Job 1 Job 2 Job 3 Job 4 Job 1 - X X Job 2 - X Job 3 - X Job 4 - Supercharged Insights, Factory Modeling, and Intelligent Scheduling Global Factory Attributes Work Calendars Material Delivery Control Points Resource Capacities Learning Curves Other Attributes of Interest Originating Organizations Current Condition of Assembly Historical Manufacturing Data Aircraft and Factory Systems Classifications Value Increases Over Time All Models Are Wrong, Some Are Useful George Box
- 9. 9 Copyright 2023 Prestin Group LLC How to Start Right: Factory and Process Design Design in Resiliency and Remove Improvement Curve Waste from the Start DSMs Rapid Data Collection Factory Layout Design Constraints Analysis Network Visualizations and Analytics Multiple Perspectives Complexity Analytics AI Powered Intelligent Scheduling Capacity Planning Economic Profit Optimization Workforce Planning
- 10. 10 Copyright 2023 Prestin Group LLC How to Stay Right: Production Management and Breakthrough Improvement Production Management Optimize for minimum flow time, maximum resource utilization, and strategic margins of safety Adaptable and Actionable Priorities = Rapid Resolution DSM’s and Intelligent Scheduling allow for rapid replanning, scenario analysis, long range strategic planning, and more Breakthrough Improvement Root cause analysis scale up/down in factory, process, and product hierarchies for holistic points of view Identify “As Performed” bottlenecks and alternative solutions Partition across Multi-Domain Matrix to assign high leverage improvement focus areas and ensure proper accountabilities Historical Performance Data Partitions and Hierarchies Position for Adaptation and the End of Incremental Improvements Planning Network Configurable Schedules Resourcing and Priorities
- 11. 11 Copyright 2023 Prestin Group LLC Our point of view on the industry Evolving 20% Status Quo 80% A&D INDUSTRY GRAPH BASED METHODS MATURITY • In A&D, outsized benefits make the difference between growth and decline • How to get Analogue transformed to Digitals world? • Strategy, Strategy, Strategy • Great Product Management • Great Program Management • Customer and User Empathy • Proven Results in Variety of Manufacturing Environments
- 12. 12 Copyright 2023 Prestin Group LLC Key Takeaways Anyone Can Use Graph Based Solutions solve General Problems Domain Expertise coupled with Graph Based Solutions makes for a powerful combination No technology or method fits all cases, be flexible and general to be successful Model from simplicity to sophistication and deliver value along the way
- 13. 13 Copyright 2023 Prestin Group LLC THANK YOU linkedin.com/in/davidprestin theprestingroup@gmail.com www.daveprestin.me
Editor's Notes
- #6: Analogue Manufacturing: Sad Stan is Our Operations Manager Fragmented and unconnected factory Leads to “each his own” Try to compensate with increasing spans of control and layers of management vs. part of the system itself Typically performance is measured by “how bad were you in the past” – like jobs behind schedule, cost variance, etc. Stuck in Frederick Taylor or otherwise known as Taylorist Methods Derived from a simpler and ordered world Designed around the organization structure – Conways Law, factories initially organized by type/categories of work usually aligned to engineering and program org structures Reductionist and fragmented thinking Results in chasing variance and making metrics look better Digital Manufacturing: Happy Heather is our Operations Manager Product and Process Designed with Digital Twins Values driven that People and their relationships come first – Networks and relationships dominate thinking across Product – Process – Technology Systems are built for resilience and adaptation – like natural ecosystems evolved to be Built in Evolutionary processes and Thinking DSM’s aid design and adaptive decision making Network Insights point to pain points and outsized opportunities to improve performance Intelligent Scheduling aids in coordination, connectivity, and collaboration
- #10: DSM’s Enable Rapid data collection and analysis Scalable 2D is very approachable! Factory partitioning and level loading layouts Design in process simplicity Constraint identification and alleviation Design-out disruption potential Network Visualizations and Analytics Enable Diverse visualizations See from multiple perspectives for better results Numerical complexity analytics Laser focused process/product design feedback AI Powered Intelligent Scheduling Enables Factory Layout Capacity Planning Right size aircraft inventory, build in buffers Economic Profit Optimization WIP, Flow Time and Throughput alignment Workforce Planning Right people, right roles, right time, right place