Module Corporate Knowledge Management

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					                                                         Copyright

This presentation is the property of:
 National Center for Advanced Manufacturing (NCAM)
 Integrated Manufacturing Technology Initiative (IMTI)

Conditions of Use:
 This presentation is intended for non-profit
  educational, academic, and research purposes and is
  not intended for commercial use and is not for resale.
 NCAM and IMTI should be acknowledged as the
  source of this material.

                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                  Summary Slide

 Welcome to the Knowledge Applications
  Seminar




               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
Welcome to the Knowledge
  Applications Seminar
         Presented By
       Richard Neal and
          Ray Walker


        Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                           The Agenda
   Introduction
   Knowledge Acquisition, Storage, and Retrieval
   Knowledge Applications in Design
   Break
   Knowledge Applications in Manufacturing
   Corporate Knowledge Management
   Summary and Path Forward

              Our Agenda is Your Agenda
         We hope That You Will Interact With Us

                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
Module 1 - Introduction




     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         The Goals of This Seminar

 To improve the understanding of what can be
  and is being done with knowledge in design and
  manufacturing.
 To highlight successes and solutions, which can
  be emulated by your organization.
 To point to the future opportunities and
  applications.


                  Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
The Integrated Manufacturing Technology Initiative




                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                           Background
NASA and the NCAM sponsored a workshop on
the topic of Knowledge Management for Design
and Manufacturing
   64 people attended
       21 Industry
       9 Technology Suppliers
       12 Government
       11 Research community (Labs plus academics)
   Excellent interchange!

                Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
     Some Foundational Definitions:
                        Knowledge

 The Objects, Concepts and Relationships that
  are accepted as truth in some area of interest
 Knowledge differs from data or information in
  that new knowledge can be created from
  existing knowledge by inference.


             Thanks to Bill Simons of Honeywell Federal Manufacturing and Technologies



                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
              A Working Definition of
                        Knowledge
Knowledge:
The "Know how " with respect to objects, concepts,
  and relationships that exist within the field of
  Product and Process Design, Manufacturing
  Planning and Execution, and Corporate
  Management - including life-cycle issues




                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
       Some Foundational Definitions:
            Knowledge Management
 The collection of processes by which organizations
  create, acquire, process, and apply knowledge
  assets, especially with technology know-how, in
  support of their core business practices
Other inputs from various sources:
 Getting the Right Knowledge, to the Right People, at the
  Right Time, and at the Right Cost.
 Making the most of what we know
 The practice of getting information and intellectual resources
  to an individual or team when they need it.
                          Thanks to Bill Simons of Honeywell Federal Manufacturing and Technologies


                        Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 A Design and Manufacturing Centric
                          Definition


Knowledge Management is the collection of
activities by which product designers and
manufacturing practitioners create, acquire,
process, and apply knowledge assets for
lifecycle product value.

                                              Adapted from input by Bill Simons




              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
              An Accepted Knowledge
                  Management Model

                Socio-Cultural Issues


Knowledge      Knowledge
                                     Knowledge                Knowledge
 Creation/       Storage/
                                     Distribution             Application
Acquisition    Organization


                       Technology




                         Source: http://www.rhsmith.umd.edu/is/malavi/icis-97-KMS/sld011.htm

                  Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
          The Perspective for Today
 Our real interest is in the result.
 Management may imply investment - application
  implies success.
 We appreciate the individual achievements, but
  we also anticipate a totally integrated,
  knowledge rich environment.

               Thought for the Day:
    It Doesn’t matter if a Cat is Black or White,
           As Long As It Catches Mice
                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
The Total Vision - Integrated Product Realization In
        a Knowledge Based Environment




                  Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
Another View That is Not As Sequential




     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
Knowledge Based Product Life-Cycle Management




                Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
Knowledge-Centric Enterprise




  Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
A Knowledge Rich, Model-
           Based Vision




      Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
The Functional Model




Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                The Seminar Process

 We will present modules according to the
  functional model.
 We want this to be a discussion, not a lecture.
 Please interact with us by submitting text
  questions through the Webtrain system at any
  time.
 We will discuss questions between each
  module.

                Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
          Module 2

Knowledge Acquisition, Storage,
        and Retrieval




          Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                            Knowledge Acquisition,
                             Storage, and Retrieval
                  Knowledge Management For
                   Design and Manufacturing



 Knowledge        Knowledge                     Knowledge                    Corporate
                  Applications                 Applications In              Knowledge
Acquisition,       In Design                   Manufacturing                Management
Storage, and
  Retrieval
  • Knowledge Capture
  • Knowledge Storage and Management
  • Knowledge Validation and Control
  • Knowledge Retrieval


                        Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                       Knowledge Acquisition,
         Knowledge Management
                  For
        Design and Manufacturing




                                        Storage, and Retrieval
 Knowledge
Acquisition,
Storage, and
  Retrieval




   The capture, storage, currency, controlled access,
   and user interface in managing knowledge

    Anticipates knowledge-based design and manufacturing
    Embraces the task of reliably providing:
                The knowledge that is needed,
                where it is needed,
                in the form in which it is needed, and
                at a cost that enables the enterprise


                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                                             The Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval




     Current, best knowledge will be available
     to drive all enterprise functions as part of
     a knowledge-based design and
     manufacturing environment and without a
     cost burden.



                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
           Knowledge Management
                    For




                                                      Knowledge Capture
          Design and Manufacturing


   Knowledge
  Acquisition,
  Storage, and
    Retrieval




                 Knowledge Capture
                                                                              Emerging Best
   Lagging Practice                   State Of Practice                          Practice
• Manual Knowledge                   • Expert Interviews for             • Text and Data Mining
  Capture                              Knowledge Capture                 • Neural net applications
• Limited Application of             • Snapshots in Time                 • Knowledge Discovery
  Lessons Learned                    • Systematic Work                   • Multimedia Packaging
• Maintenance of Current               Processes
  Knowledge is a Barrier                                     • Systematic Processes –
                                     • Knowledge-based Supply With Toolsets
• Lack of Business Case                Chain Management
  Analysis                             (ERP)                 • “Knowledge Objects”
                                                               Capture Operational
• Cultural Deployment                • Knowledge Capture       Knowledge to Build an
  Barriers                             Priority for Critical   Integrated Knowledge
                                       Services                Set

                                       Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Capture

       Procter & Gamble used agent-based modeling to
        capture knowledge inherent in supply chain events,
        resulting in an inventory reduction of 25% with a
        simulation developed by BiosGroup.
       Lilly’s online knowledge broker, InnoCentive, solves
        40% of the R&D problems posted by companies like
        BASF and P&G by seeking solutions from scientists
        around the world.
       Ninesigma is a neutral knowledge broker with over 40
        major clients

                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                                     Large Companies Seek
         Knowledge Management
                  For
        Design and Manufacturing


 Knowledge
Acquisition,
                                                                     Knowledge Outside the
                                                                               Boundaries
Storage, and
  Retrieval



               Knowledge Capture
                  U.S. Industrial R&D Percentage by Enterprise




       Size




                         Source: Harvard Business School via http://www.ninesigma.com/solutions/index.html

                                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Capture

       PLM toolkits include knowledge-based development
        toolkits
       Tinker Air Force Base is managing the repair and
        maintenance functions using toolsets from KBSI
       NNSA programs focused on critical knowledge
        capture
       The Automated Knowledge Discovery System
        automatically categorizes knowledge against
        technology roadmaps utilizing ontologies

                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                                          The Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Capture



         Knowledge is preserved. Systems will
         automatically extract knowledge from all
         available sources and process for best
         utilization. Human knowledge capture will
         be effective and non-intrusive, and will
         include learning capability.

                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                      Strategy for Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Capture
       Promote a Knowledge Management culture to
        facilitate effective knowledge capture, storage, and
        retrieval.
       Benchmark and document existing tools, best
        practices, success stories, and lessons learned for
        knowledge capture, storage, and retrieval. Identify
        technical gaps for focus.
       Develop standardized, state of the art methodologies
        and processes for effective knowledge capture,
        storage, and retrieval.

                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                    Knowledge Storage
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Storage
                                                                            Emerging Best
 Lagging Practice                   State Of Practice                          Practice
• Relational Databases             • XML And Variants                   • Single Source
• Lack Of Standardization • No Standardized                               Documentation
• Lack Of Robust            Architecture For                            • Neutral Files Format
  Representation Of         Repositories                                • Data and knowledge
  Knowledge                        • Relational And Object                warehouses
                                     Oriented Databases                 • “Knowledge Gardens”
                                   • Traditional IT Methods               and other
                                     Applied To Knowledge                 storage/presentation
                                     Management                           structures




                                     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Storage

      Daimler Chrysler’s won Motor Trend Car of the Year
       for the Chrysler 300M and Petersen’s 4X4 of the
       Year Award for the Jeep Cherokee using the
       “Engineering Book of Knowledge”.
      The Frito-Lay wrested insights from its data
       warehouse that enabled it to evaluate potato skin
       suppliers and consolidate purchasing, saving $10
       million in just one year. Across the organization, a
       50% reduction in stale inventory and an increase in
       sales by 40% over three years resulted.

                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                                          The Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Storage


          Dynamic storage of an infinite volume of
          knowledge with:
            Assurance of the right knowledge
            Maintenance of all needed knowledge
            Low cost
            Highly secure


                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                      Strategy for Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Storage


       Develop standard knowledge representations
        (formats) that will facilitate effective
        knowledge capture, storage, and retrieval.
       Develop automated tools that put knowledge
        where it needs to be and supports the ready
        access by the user



                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                             Knowledge/Data
         Knowledge Management
                  For
        Design and Manufacturing




                                                                Maintenance
 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge/Data Maintenance
                                                                             Emerging Best
 Lagging Practice                   State Of Practice                           Practice
• Dedicated Data                   • Application of Traditional • Knowledge Management
  Management Staff                   IT Methods                   Throughout the Supply
• Management Based on              • Knowledge Systems            Chain
  Life Expectancy                    Operate with Static Data           • Integrated Product Data
• Poor Integration of              • Inefficient Knowledge                Management
  Systems                            Capture Makes                      • Data Integrated with PLM
• Costly, Unsystematic               Maintenance Impossible               and ERP Systems
  Knowledge Maintenance                                                 • Automated latest
                                                                          knowledge verification
                                                                          and duplication
                                                                          elimination

                                     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                                             The Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge/Data Maintenance

          Knowledge And Data Management Will Be:
             Intuitive
             Traceable
             Migrated seamlessly (for currency)
             Continuously updated and edited (for
              disposal, conflict resolution, historical
              significance, etc.)
             Self adaptive
             Low cost
                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                      Strategy for Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge/Data Maintenance



       Develop automated system to detect
        knowledge base contradictions and then
        resolve those contradictions
       Develop improved standards for API’s
        (application programming interfaces) and
        architectures.


                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                       Knowledge Validation
         Knowledge Management
                  For
        Design and Manufacturing




                                               and Control
 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Validation & Control
                                                                             Emerging Best
 Lagging Practice                   State Of Practice                           Practice
• Nonexistent or Manual            • Ad Hoc Validation                    • Theoretically-driven,
  Data Validation                  • Domain Expert Review                   Scientific Validation
• Large Volumes of Data / • Refereeing, as in Journal                     • Expert Panels
  Knowledge Negate          Articles                                      • Automated Validation
  Validation
                                                                          • Federal Initiatives to
• Lack of Validation Criteria
                                                                            Form Guidelines
• Lack of Acceptance for
  Need




                                     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Validation & Control



      General Motors has reduced cycle time
       through “repeatable digital validation” – data
       are made available on a single platform for
       retrieval in real time by the design team




                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                                          The Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Validation & Control


         Knowledge will be well quantified and founded
         on scientific principles:
                   Model based validation will be part of all
                    knowledge capture
                   Conflict resolution, traceability, linkage to
                    other knowledge and other functions will be
                    background functions


                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                           Knowledge Retrieval
         Knowledge Management
                  For
        Design and Manufacturing




                                                  and Delivery
 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Retrieval & Delivery
                                                                             Emerging Best
 Lagging Practice                   State Of Practice                           Practice
• Decisions Do Not                 • Effective Search Engines            • Shared Models Using
  Support Need for                 • Online Analytical                     Resource Centers
  Retrieval                          Processing Tools                    • Integrated Knowledge
• Poorly Designed                  • Collaborative Tools                   Management
  Interfaces                                                             • Search And Delivery of
• Inability to Serve the                                                   Lessons Learned
  Specific Needs of the                                                  • Automated Knowledge
  User                                                                     Discovery
• Too Much Data, Poorly                                                  • User Profiles
  Filtered


                                     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Retrieval & Delivery

  NASA ModelCenter and Collaborating Engineering
   Centers
  Integrated Knowledge Management training and delivery:
   Electronic Performance Support System (EPSS) helps
   employees perform tasks
  MBDA Missile Systems uses Teamcenter Aerospace and
   Defense for shared knowledge around the world
     Instant access to hundreds of users

     Common data management across the enterprise

     Change management and product structure control



                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Retrieval & Delivery

    NASA’s goal through EPSS implementations:
    To “enhance mission success through seamless, community-
    focused electronic service delivery” through the use of:
         portals (customizable web sites)
         e-learning technologies,
         capture and distribution of lessons learned
         communities of practice,
         and collaborative environments.
    Results so far:
         Webby and People’s Voice Awards in 2003.
         2004 International Competia Award for the leadership
                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Retrieval & Delivery

      Robert Bosch Corporation
       Implemented a data warehouse to improve
        quality control
       Using data mining techniques, they went from
        the capability to isolate problems to pallets of
        material to isolation of just the affected parts.



                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                      Best Practice Examples
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge/Data Maintenance

       UT Automotive utilizes data analysis and
        warehousing to produce in days reports that
        had taken months to produce
       They are able to track metrics that were never
        tracked before
             Quality Metrics

             Rates of test failure

             Delivery performance



                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                                             The Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Retrieval & Delivery


        Fully indexed, semantic retrieval
        capability, delivering exactly what the user
        wants to see, in the form in which they
        want to see it.




                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                          Strategy for the Vision
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval



               Knowledge Retrieval & Delivery


       Develop intuitive graphical user interface
        technology specifically designed for
        knowledge capture, storage, and retrieval.
       Develop integrated retrieval / storage system.
       Develop secure, distributed knowledge
        systems for capture, storage, and retrieval.


                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Knowledge Management
                  For




                                                  Module 2 Summary
        Design and Manufacturing


 Knowledge
Acquisition,
Storage, and
  Retrieval




       Knowledge acquisition will balance the
        capture of human knowledge with a strong
        move to a science and mathematics base
       Management of knowledge to assure
        accuracy, currency, and controlled availability
       Delivery of the right information, to the right
        person, at the right time, and at an
        acceptable cost

                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
          Module 3

Knowledge Applications in Design




          Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                       Knowledge Applications
                                   in Design
                  Knowledge Management For
                   Design and Manufacturing


 Knowledge
Acquisition,   Knowledge                      Knowledge
                                             Applications In
                                                                       Corporate
                                                                       Knowledge
Storage, and
  Retrieval    Applications                  Manufacturing            Management


                In Design
                 • Preferences and Requirements
                 • Knowledge-Based Design Scenarios
                 • Design Advisors
                 • Automated Detailed Design


                     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                             Knowledge Applications
 Knowledge Management
          For
Design and Manufacturing




                                         in Design
Knowledge
Applications
 in Design




     This element addresses the use of
     knowledge in design. It includes:
        Customer preferences and requirements
        Design advisors
        Design validation tools
        Automated design systems

                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
    Knowledge Management
             For




                                                                        The Vision
   Design and Manufacturing


  Knowledge
  Applications
   in Design




Future design systems will be knowledge processors
instead of data processors. They will capture, store,
analyze, and deliver knowledge that supports
optimized value throughout the product’s lifecycle.
Applications will be:
    Intuitive
    Adaptive
    Interoperable
    Continuously adding to the knowledge pool

                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                        Preferences and
      Knowledge Management
               For
     Design and Manufacturing




                                                           Requirements
    Knowledge
    Applications
     in Design



             Preferences and Requirements
                                                                             Emerging Best
   Lagging Practice                 State Of Practice                           Practice
• No Standardized Templates • Document-based                          • Requirements Tracing And
• Inadequate Systems          Requirements                              Workbenches
  Engineering                   • Use Of Related                      • Preferences Drive
• Unsystematic                    Requirements                          Requirements
• Lack Of Common Semantics • Quality Function Deployment • Model-based Specifications
• Failure To Commercialize • Uncertainty And Risk Not    • Traceability Of
  Knowledge Management       Well Quantified               Requirements To Design
  Tools                    • Systems engineering           Specs
                                                                      • Use-case Models
                                                                      • Standardized Requirements
                                                                      • Automated Test Suites
                                                                      • Recycling Requirements

                                  Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design



         Preferences and Requirements
Boeing Corporation’s 777
 Slashed product cycle development time by 91%
  and cut labor costs by 71% by:
         working more closely with customers early on to understand
          requirements and constraints
         giving stakeholders access to a virtual prototype
         combining virtual private and secure public networks for
          collaboration with 75-plus design teams
         making dataset accessible through common applications




                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                         Best Practice
 Knowledge Management
          For
Design and Manufacturing




                                                            Examples
Knowledge
Applications
 in Design




         Preferences and Requirements


 3M, Cummins, and Raytheon are among the
  customers for Cognition’s 6-σ Cockpit toolset
  which records, weights, and prioritizes
  customer preferences and creates a
  performance “supermodel” which links all
  critical parameters to their sources and their
  drivers



                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
  Knowledge Management
           For



                                                                        The Vision
 Design and Manufacturing


 Knowledge
 Applications
  in Design



          Preferences and Requirements

Future design systems will equate customer preferences
and requirements to product features and functions early
in the conceptualization phase, and will apply knowledge
to quickly and automatically converge to an optimized
conceptual design

          A pyramid of information
                 Starts with customer preferences
                 Processes to a complete solutions concept



                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For
Design and Manufacturing              The Master Model for
Knowledge
Applications
                                 Knowledge-Based Design &
 in Design
                                            Manufacturing
         Preferences and Requirements




                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                              Strategy for Vision
Design and Manufacturing


Knowledge
Applications
 in Design



         Preferences and Requirements

   Develop the capability to process needs and
    preferences to requirements.

   Incorporate risk, uncertainty, cost, and other
    factors in processing of requirements.

   Develop intuitive user interfaces for
    requirements evaluation.


                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                     Knowledge-Based
      Knowledge Management
               For
     Design and Manufacturing




                                                     Design Scenarios
    Knowledge
    Applications
     in Design



             Knowledge-Based Design Scenarios
                                                                          Emerging Best
 Lagging Practice                State Of Practice                           Practice
• Consensus On                  • Collaborative Tools For
                                                                      • Trade-off Environments
  Parameters And                  Interactive Design
  Weighting                                                           • Dynamic Connection To
                                • Heavy Reliance On
• Limited Solutions               Standard Toolsets                     Knowledge Base
• Omits Some Relevant           • Modeling and Simulation • Managed Knowledge
  Attributes                      for evaluating options    Versus Static Knowledge
• Lack Of Explicit              • Not Integrated With                 • Methodical Optimization
  Knowledge                       Detailed Designs
• Costs Impacted By             • Course-level Analysis
  Conceptual Phase              • Experimental
                                  Optimization

                                  Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design



         Knowledge-Based Design Scenarios

 Immersive collaborative environments are being used
  to evaluate design options in an integrated project
  team environment.
 The Integrated Manufacturing Technology Institute in
  London Canada utilizes immersive environments in
  working with the automotive industry. Several
  examples can be cited of major problems avoided
  through scenario-based product evaluation.


                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                          Best Practice
  Knowledge Management
           For
 Design and Manufacturing




                                                             Examples
 Knowledge
 Applications
  in Design



          Knowledge-Based Design Scenarios


 Companies like Pratt & Whitney, Lockheed-
  Martin, and PSA/Citroen, are using Cognition
  Knowledge Center® to evaluate cost options.
  The system not only supports cost trade-offs,
  but establishes a complete value management
  program from requirements to as-built results.




                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design



         Knowledge-Based Design Scenarios

 Iomega brought HipZip, portable digital audio player
  to market in 11 months, achieving a 50% reduction in
  product development cycle time by:
         Using an integrated design, drafting and tooling operation
         Utilizing 3D solid models in an concurrent conceptual design
          process
         Linking computer-aided design, manufacturing, and
          engineering technology to rapid prototyping technology to
          support a concurrent engineering approach



                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
  Knowledge Management
           For



                                                                      The Vision
 Design and Manufacturing


 Knowledge
 Applications
  in Design



          Knowledge-Based Design Scenarios

Design concepts will be automatically generated by
knowledge based processors that accept requirements
and produce alternatives

     Alternatives evaluated for all business, technical,
      and aesthetic parameters
     Integration with detailed design




                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                              Strategy for Vision
Design and Manufacturing


Knowledge
Applications
 in Design



         Knowledge-Based Design Scenarios

 Establish forward and backwards traceability
  of product knowledge mapped to
  requirements
 Implement corporate culture change to
  support a knowledge sharing environment.
 Develop automated, knowledge-based model
  generation and abstraction capabilities.


                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                Knowledge Based
 Knowledge Management
          For
Design and Manufacturing




                                               Conceptual Designs
Knowledge
Applications
 in Design



         Knowledge-Based Conceptual Designs
                            Scientific Knowledge                    Decision
    Technical                                                   Recommendations
    Requirements                                                  and Rationale



                                                                               Visualization
                           Concepts Processor                                 of Alternatives



                                                                         Detailed Design
    Business
    Issues                   Experiential Data

                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                     Design Advisors - Product
     Knowledge Management
              For
    Design and Manufacturing


    Knowledge
    Applications
     in Design
                                          and Process Design
             Design Advisors
                                                                        Emerging Best
 Lagging Practice               State Of Practice                          Practice
• Single-function Advisors • Specialized, In-house                  • Semantic Technologies
• Static Knowledge           Advisors                                 Integration
• Experimental Basis And       • Common, Repetitive                 • Knowledge-based
  Legacy Systems                 Design                               Conceptual Engineering
• Ad Hoc Procedures            • Single-function Domains • Knowledge linked to PLM
• Semantic Errors              • Automated Tool Path     • Rule-based Design For X
                                 Generation / Process
• Limited To Product                                     • Process Simulation
                                 Planning
  Design                                                   Coupled With Rule-
                               • Concurrent Engineering    based Systems
• Mostly “Simple” Families
  Of Parts

                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design



         Design Advisors


 Rockwell Collins implementation of a design for
  manufacturability advisory system

 Cummins automated design of critical components

 Many examples in the automotive and aerospace
  sector




                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design



         Design Advisors

Many examples in the automotive sector
Jaguar:
 Bonnet (hood) inner panel design - Creates sheet
  metal surfaces of the inner panel based on the studio
  surface of the hood
 Direct and indirect Field Vision - Studies the occupant
  direct field of view and performs various analyses
  and evaluates conformance to government
  regulations


                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design



         Design Advisors

Many examples in the automotive sector
US Auto Manufactures:
 Transmissions - Hydraulic circuit layout and design
 Crankshaft - Parametric rule based design
  application
 Drive line layout
 Rack Density
 Stamping Die design automation

                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
  Knowledge Management
           For



                               Best Practice Examples
 Design and Manufacturing


 Knowledge
 Applications
  in Design




          Design Advisors

Northrop Grumman developed an automated tool design
advisor for a program for the U.S. Navy

      97% savings in the total cost of design of graphite
       tools
      60% savings in the total cost of design of steel tools
      Cut design time from days to hours



                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
  Knowledge Management
           For



                                                                      The Vision
 Design and Manufacturing


 Knowledge
 Applications
  in Design



          Design Advisors

Future designs will be created using design
advisors that synthesize knowledge from an
extended value chain and harness the creative
power of human input.
         Explores the complete design space
         Supports a tradeoff environment
         Linked to analysis tools (modeling and simulation)
         Engages the designer (and perhaps the customer?)
         Integrated with the conceptual design system

                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                              Strategy for Vision
Design and Manufacturing


Knowledge
Applications
 in Design




         Design Advisors

 Develop a standard framework for design
  advisors
 Develop knowledge capture methodologies
  that support decision making.
 Develop automated generation of models that
  support real-time analysis of design options


                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                              Automated Detailed
     Knowledge Management
              For
    Design and Manufacturing




                                                         Design
    Knowledge
    Applications
     in Design



             Automated Detailed Design
                                                                       Emerging Best
 Lagging Practice              State Of Practice                          Practice
• Lack Of Standards That • Automated Design Within                 • Tool Independent Design
  Support Automated         Domains                                  Capability across
  Design                  • Designs Are Limited To                   domains
• Proprietary Formats For   Functional Areas Lacking               • Feature-based design
  Design Tools              Integration Across The                 • Knowledge Separated
• Cultural Barriers Limit   Product Lifecycle e.g.                   From The Tool
  Utilization               mechanical, electrical,
                            chemical process                       • Modular Plug-and-play
                                                                     Designs
                                                                   • Model-based
                                                                     Engineering


                               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design




         Automated Detailed Design

 Fluor - automated design for capital projects
 By capturing and codifying knowledge, the
  virtual SLICE team within Rocketdyne at
  Boeing:
         designed a rocket engine thrust chamber using 6
          parts instead of 1,200
         reduced manufacturing costs from $7 million to
          $0.5 million
         exceeded the current industry best practice of 6
          sigma when it predicted a quality level of 9 sigma

                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                              Best Practice Examples
Design and Manufacturing


Knowledge
Applications
 in Design



         Automated Detailed Design
The Tech Group, a global leader in injection molding
manufacturing solutions for the medical and consumer
industries, achieved:
         20 to 25 percent gain in overall productivity
         50 to 75 percent gain in quality, and is
         attained Six-Sigma certification
…using Mold Wizard technology to automate mold
designs, including automated updates for design
changes



                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
  Knowledge Management
           For



                                                                      The Vision
 Design and Manufacturing


 Knowledge
 Applications
  in Design



          Automated Detailed Design


Detailed design will be the result of a progressive,
adaptable, model-based process that anticipates the
knowledge, information, and data that is needed for the
total project lifecycle and provides it in the right format, at
the right place, at the right time.
The design represents the best value for cost, compliance,
capability, performance, and all other business and
technical attributes.


                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                              Strategy for Vision
Design and Manufacturing


Knowledge
Applications
 in Design




         Automated Detailed Design


  Develop linkages to knowledge storage to
   assure complete capture of design processes
   and retention of all relevant information.
  Develop capability to produce integrated
   designs across domains.
  Achieve Interoperability of design tools.


                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                           Module 3 Summary
Design and Manufacturing


Knowledge
Applications
 in Design




From needs, to requirements, to conceptual designs, to
detailed designs - including the supply of all information
to drive downstream applications - in a knowledge
enabled environment
         The pieces are in place
         PLM systems are stepping up – from the modeling side
         Successes are being realized
         The challenge is the interoperable toolset and radical
          departures from the evolutionary approach



                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
       Module 4

Knowledge Applications in
     Manufacturing




       Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                  Knowledge Applications In
                            Manufacturing
                 Knowledge Management For
                  Design and Manufacturing


 Knowledge
Acquisition,
               Knowledge
               Applications            Knowledge                               Corporate
                                                                               Knowledge
Storage, and
  Retrieval
                In Design
                                      Applications In                         Management


                                      Manufacturing

                                      • Process Planning
                                      • Process Control
                                      • Certification of Product and Process
                                      • Lifecycle Management


                       Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                           Knowledge Applications In
 Knowledge Management
          For
Design and Manufacturing




                                     Manufacturing
         Knowledge
        Applications in
        Manufacturing




       Includes all activities where knowledge is
       applied to plan or execute manufacturing
       processes, including the certification of product
       and process and lifecycle product management.




                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                     The Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing




        Future manufacturing systems will be
        intelligent. Planning will be done based on
        scientific and empirical knowledge resulting in
        the creation of a control model. The execution
        of the process will be handled for best results
        - including proactive response. The
        knowledge base and models will be updated
        with each execution.


                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
   Knowledge Management
            For



                                                      Process Planning
  Design and Manufacturing


           Knowledge
          Applications in
          Manufacturing



              Process Planning
                                                                        Emerging Best
 Lagging Practice                State Of Practice                         Practice
• No Systematic Way to       • Rule-based Planning                  • Holonic Manufacturing –
  Capture process            • Experience-based                       Planning Based on
  Knowledge                    Automation (isolated)                  Social Understanding of
• Ineffective Feedback                                                Components (ant hills)
                             • Process Planning
  From Manufacture to          Becoming Part of                     • Virtual Manufacturing of
  Design                       Integrated Systems                     equipment
• Reliance on Experts        • Model-driven Planning                • Knowledge-based
• Disjointed Flow of                                                  Tolerancing
                             • M&S capabilities
  Knowledge                    fragmented                           • Automated Planning
• Manual translation of      • CAPP                                 • Linkage to STEP
  CAD data into CAM

                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                  Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Planning

  NCMS CTMA HI-Thru programming of five axis
   high speed machine. Automated generation of
   machine tools path plans demonstrated at
   Cincinnati Milacron.

  Automated rolling schedules at Lockheed Martin
   based on captured process knowledge and
   customer requirements.

                               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                  Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Planning

    At Honeywell, FB Mach and FB Tol apply knowledge
     based systems to provide fully toleranced product
     models and to determine the optimum processes
     based on product features.
    Nova Chemical – Demand Based Process Design
           Automatically designs AND configures the factory for best
            response




                               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                         The Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Planning

        Process planning will be the automated result
        of the application of knowledge to the design
        requirements.
                  Requirements may be geometric, scientific
                   representation e.g. chemical formula, or the
                   output of any product model.
                  Process planning will optimize performance to
                   deliver best total value.


                               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                  Strategy for Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Planning

    Model the “process” of “process planning”
     (methodology), develop process plan optimization
     tools, and establish methods for the collection and
     use of best practice knowledge.
    Implement dynamic corrective action and traceability
     integrating process plans with downstream
     processes, upstream processes, and product models.




                               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
    Knowledge Management
             For



                                                             Process Control
   Design and Manufacturing


            Knowledge
           Applications in
           Manufacturing



               Process Control
                                                                          Emerging Best
  Lagging Practice                 State Of Practice                         Practice
• R&D Knowledge not              • Limited Capability for            • Multiple Sensors
  Supporting Production            Direct Measurement                  Integrated into a Single
                                                                       Chip
• Lack of Integration of         • Controllers do not
  Sensors and Actuators            Support Decisions                 • Flexible, Open
                                                                       Architecture
• Difficulties Using Multi-      • Modeling and Execution
  sensor Data                      Not Linked             • Hierarchical Control
                                                            Structures
• Legacy Actuator                • Statistical Process
  Knowledge                        Control                • Self-adjusting, Smart
                                                            Systems
• High cost of sensors &         • Basic Equipment
  controls                         Monitoring             • Intelligent Control
                                                          • Remote Monitoring &
                                                            Control
                                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                 Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Control
    Johnson Controls’ Automotive Systems Group
     improved first product correct capability by 28% in 5
     years and reduced raw material cost by 60% through
     the application of technology, and continuous
     improvement to better control processes.
    BP Amoco achieved 95% closed-loop operation and
     saved $500,000 per year by implementing intelligent
     control for separating pretreated crude oil into product
     streams. With the conventional system, changeover
     took 30 minutes, now within minutes.



                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                 Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Control


    LTV Steel saved $10M by reducing roll marks in sheet
     metal rolls using data mining to isolate and solve
     manufacturing variability problems.
    Robert Bosch Corporation implemented a data mining
     based quality control solution to quickly retrieve and
     graphically see test results for all manufacturing
     processes. The new system paid for itself when
     workers saved about 80% of the units on a pallet. In
     past practice, the whole pallet would have been lost.


                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                 Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Control


    The Department of Energy sponsored a Precision
     Flexible Manufacturing System project that produced
     edge-of-the-art, intelligent machining and inspection
     equipment, all utilizing statistically proven process
     control excellence as a foundation for product
     acceptance.




                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                 Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Control


         Because the quality of the welds varied, an
         automobile manufacturer had to apply twice
         as many spot welds to an automobile body as
         conservative engineering would specify. The
         Oak Ridge National Laboratory developed a
         neural network based system that analyzed
         and optimized the weld – in process
         delivering dramatic cost savings


                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                        The Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Control


   Intelligent Real-time Control of all Processes
               In-process, non-intrusive inspection/evaluation
               Self-verification and validation of processes
               Knowledge-based validation
               Real-time process control integrated with process
                verification




                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                 Strategy for Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Process Control

    Develop understanding of elements to monitor in
     process control models and develop control
     algorithms to enable self-monitoring, self-diagnosis,
     self-regulating, and self- healing capabilities.
    Develop necessary affordable, intelligent sensor
     technologies (devices etc.), sensing strategies, and
     technologies.




                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                         Verification of Product
    Knowledge Management
             For
   Design and Manufacturing




                                                    and Process
            Knowledge
           Applications in
           Manufacturing



               Verification of Product & Process
                                                                          Emerging Best
 Lagging Practice                State of Practice                           Practice
• Direct Measurement of        • Measurement and                     • Process Assurance for
  Product Features               Testing for Quality                   Quality
• Variation in Product   • Statistical Process                       • In-process Validation of
  Quality Based on Human   Control                                     Process and Equipment
  Factors                • Periodic Validation of                    • Interactive Tasks with
                           Process / Equipment                         Real-time Training
                               • Operator Compliance                 • Institutionalization of 6-
                                 Training and Certification            sigma for Knowledge
                                                                       Management




                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                 Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Verification of Product & Process

   The Oak Ridge Y-12 Plant had one shot at producing a
   critical component for the Navy, and it had to be done
   quickly.
           Machine was on order
           Part blanks were being produced
   They utilized modeling and simulation and existing
   knowledge to develop and verify processes, and they
   were ready to produce product as soon as the machine
   was in place.

                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                        The Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Verification of Product & Process


        Knowledge-based validation and
        verification will use in-process evaluations
        and will measure and control processes to
        verify product. There will be feedback
        capability for dynamic corrective action
        for process plans and model updates.



                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                 Strategy for Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Verification of Product & Process

    Develop an understanding of model elements used to
     verify and validate what defines a good part.
    Develop the algorithms for comparison of predicted
     outcomes to actual outcomes.
    Develop in-process visualization methods, knowledge
     foundations, and models for verification and
     validation of product.




                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
    Knowledge Management
             For



                                   Life-Cycle Management
   Design and Manufacturing


            Knowledge
           Applications in
           Manufacturing



               Life-Cycle Management
                                                                        Emerging Best
 Lagging Practice              State Of Practice                           Practice
• Knowledge Interfaces        • Field Service Data Used             • Remote Monitoring
  Between Production and        to Track Product                      Against Expected Norms
  Design                        Performance                         • Life-cycle Modeling and
• Processes are often         • Life-cycle Means                      monitoring (RF tags, etc.)
  viewed as “one time           Packages of Tools from a • Diagnostic Models
  necessities” – no lifecycle   Single Vendor
  view of processes                                      • Compliance Advisors
                              • Fear of Liability Drives
                                knowledge and Risk       • Responsibility for Product
                                Management                 moving to the OEM




                                Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                  Best Practice Examples
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Life-Cycle Management
   Design anywhere, build anywhere, support anywhere –
   in a single product life cycle system.
   Rockwell Automation replaced three separate product
   data management systems with a single PLM system
   to manage critical activities across the world. Rockwell
   was able to:
              cut engineering change notice cycle time in half,
              reduce cost per ECN by $200, and
              save $400,000 annually in just one business unit
              Achieve ready support of products


                               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management




                                                                             Vision
          For
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Life-Cycle Management



         Life-cycle management of production
         systems and product will enable knowledge
         flows among manufacturing functions and
         other critical enterprise functions and manage
         the integration of product life cycles with
         production system life cycles.



                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                          Strategy for Vision
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing



            Life-Cycle Management

           Develop and apply “life cycle concepts” in the
            management of the production system.
           Integration of product life cycle with the production
            system life cycle (long production over changing
            machine base and process technologies).
           Product and production system knowledge flows
            (e.g. process capability improvements, new
            technologies, product changes,) among
            engineering, manufacturing and other enterprise
            functions.

                            Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                          Module 4 Summary
Design and Manufacturing


         Knowledge
        Applications in
        Manufacturing




   The current state is characterized by:
           Use of data, not knowledge
           ERP, PDM, and PLM as prominent systems
   The vision for the future is of a totally
   integrated, knowledge-based capability to make
   the best business and technology choices for all
   corporate/enterprise functions



                           Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
          Module 5

Corporate Knowledge Management




          Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                        Knowledge Applications In
                                           Corporate Knowledge
                                                   Management
                  Knowledge Management For
                   Design and Manufacturing

 Knowledge     Knowledge                Knowledge
Acquisition,   Applications            Applications In            Corporate
Storage, and    In Design              Manufacturing
  Retrieval                                                      Knowledge
                                                                 Management
                                                   • Managing Critical Capabilities
                                                   • Regulatory Compliance
                                                   • Managing Human Assets
                                                   • Liability and Risk
                                                   • Managing Technology Investment


                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                      Corporate Knowledge
 Knowledge Management
          For
Design and Manufacturing




                                              Management
                 Corporate
                Knowledge
                Management




   Includes all activities associated with the use of
   knowledge to position a corporate entity or
   enterprise to perform its design and
   manufacturing function well – now and in the
   future.




                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                             The Vision for Corporate
 Knowledge Management
          For
Design and Manufacturing




                             Knowledge Management
                 Corporate
                Knowledge
                Management




       Knowledge is managed and applied to
       assure best value to the enterprise in all
       aspects of corporate operation. The
       best value equation is based on
       satisfying the business goals of the
       corporation.


                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                                       Managing Critical
    Knowledge Management
             For
   Design and Manufacturing




                                                           Capabilities
                    Corporate
                   Knowledge
                   Management




           Managing Critical Capabilities
                                                                         Emerging Best
 Lagging Practice                State Of Practice                          Practice
• Focus On Driving ERP    • Focus on differentiating                • BERP (Beyond ERP)
• Lack Of Acceptance of a   core competencies                         Using Emerging
  Knowledge Applications • Product Data                               Technologies
  Basis for Corporate       Management                              • Automated Design AND
  Management              • ERP Systems                               Management Systems
• Incompatible Systems          • Product Lifecycle                 • Real-time Systems To
• Limited Visibility Of ROI       Management - Supplier               Control Enterprise
                                  Specific                            Resources
                                • Product Management –
                                  Design to Existing
                                  Capability

                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                Best Practice Examples
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Managing Critical Capabilities

    Sony – Biological Manufacturing
           Autonomous intelligent systems for configuring products.
            Intelligent systems release control to the humans, only as
            needed
    Lockheed Martin – Horizontal and Vertical Integration
           Integrates 5 different ERP systems for intelligent enterprise
            management
    MAP – supply chain information flow
           Reducing order processing from 4 days to 1 hour
           Reducing production planning from 4 days to 5 hours

                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                 Best Practice Examples
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Managing Critical Capabilities

   Volkswagon – Comprehensive B2B
              A single point interface with all suppliers
              Collaborative processes
              Logistics tools
              Online change management
              Online quality management
              Personalized communication with each supplier
              Incorporates Knowledge Based tools
   Net IMO - Japanese strategy for establishing IT
    driven enterprises that control manufacturing

                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                       The Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Managing Critical Capabilities

Enterprises will intelligently manage their
capabilities for best value based on ubiquitous
knowledge
        Real time, automated response to a broad range of
         challenges and opportunities
        Value-based response including business and
         technical issues
        Total visibility and access to all critical resources
        Seamless integration and interoperability linking
         enterprise resources
                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                Strategy for Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Managing Critical Capabilities
    Define and develop interoperability methods for seamless
     exchange of data, information, and knowledge (all resources)
     for all enterprise functions.
    Develop tools to assess response to market and technology
     change for forecasting direction and real-time response to
     speed of market / technology change.
    Develop methods for Knowledge Discovery and Acquisition –
     Knowledge enabled, just-in-time knowledge acquisition
     based on understanding of enterprise needs.




                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
    Knowledge Management
             For



                                      Regulatory Compliance
   Design and Manufacturing


                    Corporate
                   Knowledge
                   Management




           Regulatory Compliance
                                                                         Emerging Best
 Lagging Practice                State Of Practice                          Practice
• Absence Of Impact             • Front-end Assessments              • Automated Compliance
  Assessment                      By Legal Department                  And Licensing
• Unnecessary                   • Difficulties Keeping Up            • Compliance Integrated
  Requirements                    With Regulations                     Into Design
• Compliance Incompatible • Self-regulation By                       • RF Tagging Of Products
  With Available            Corporations                               With Compliance
  Technology                                                           Information
• Unsystematic
  Assessments




                                  Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                Best Practice Examples
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Regulatory Compliance

   Ferret - A text mining and automated classification
    tool that automatically manages classified documents
   Products from Cincom Corporation enable
    automated documentation that is coupled with data
    and text mining to find and resolve compliance issues
   Hoffman-LaRoche reduced their filing time for new
    drugs by a factor of 6, saving $94 million in Phase I




                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
  Knowledge Management
           For



                                                                        The Vision
 Design and Manufacturing


                  Corporate
                 Knowledge
                 Management




         Regulatory Compliance

All regulations (including global) and controls are
fully understood and managed for non-invasive
knowledge based compliance.
      Instant understanding of regulations and knowledge
       based application to specific needs
      Full visibility of all regulations and impact - as they are
       released (intelligent regulatory agents)
      Total visibility of relevant law, automated compliance
       and reporting

                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                Strategy for Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Regulatory Compliance


    Provide analysis tools for pre-analysis /
     evaluation of all applicable regulations including
     the identification of all candidate requirements,
     complete impact analysis, and the building of
     the required knowledge bases.
    Develop systems that map regulatory impacts
     throughout all organizations and processes.


                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                    Management of Human
   Knowledge Management
            For
  Design and Manufacturing




                                                  Assets
                   Corporate
                  Knowledge
                  Management




          Management of Human Assets

 Lagging Practice               State Of Practice                       Emerging Best
• Failure To Apply Lessons • Loss Of Core                                  Practice
  Learned                    Competencies To                        • Capturing Knowledge Of
• Socio-cultural Barriers    Outsourcing                              Existing Employees
  Not Addressed                • Use Of Virtual Reality             • Virtual Machines For
• Focus On Skills Rather         Tools                                Training And Operations
  Than Strategy                • Customer-defined Core              • Head-mounted
• Knowledge Not A                Competencies                         Computers
  Corporate Asset              • Varied Success In      • Skills Inventories Include
• The BCS                        Converting Knowledge To All Capabilities,
                                 Value                    Limitations, And
                                                          Affiliations

                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                Best Practice Examples
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Management of Human Assets
  Caterpillar interviews and captures exiting employee
   knowledge in multiple systems
  Lockheed Martin - complete skills inventory of all
   employees, including regulatory and non-regulatory
   information
  Knowledge-based advisory systems that capture
   operational rules for human independence
  Xerox utilized a product called Eureka to make repair
   a social activity.


                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                       The Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Management of Human Assets
Intelligent, systems based, management of human
knowledge resources providing complete visibility and
access to all human resources and skills available and
qualified for all functions of the enterprise
        Automated discovery systems that match skills to needs - not
         limited to within a company
        Virtual human resource pools
        Specification-based resource selection
        Real-time response to the changing market for employee
         knowledge management


                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                Strategy for Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Management of Human Assets
    Establish real-time access to human resource capabilities –
     Provide complete and current, real-time knowledge bases of
     characteristics and human assets of value to the
     organization, aligned against business requirements.
    Develop discovery-based Human Advisors – Provide for the
     dynamic collection of all knowledge in the enterprise,
     analysis of events, modeling of behaviors, and identification
     of opportunities. Establish the capability for conversion of
     opportunity knowledge into systems to advise human
     behavior.


                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
   Knowledge Management
            For



                                                        Liability and Risk
  Design and Manufacturing


                   Corporate
                  Knowledge
                  Management




          Liability & Risk
 Lagging Practice               State Of Practice                         Emerging Best
• Limited Use Of Risk          • Unsystematic Risk                           Practice
  Assessment                     Assessment                          • Design For Liability And
• Focus On Tax Liabilities     • Major Focus On                        Risk Mitigation
  Without Integrated             International Regulations           • Evaluation And Problem-
  Solutions                • Trend Toward Pushing                      solving With Risk
• Emphasis On Regulatory     Liability And Risk Down                   Assessment Tools
  Issues Rather Than Total   The Supply Chain                        • Data And Text Mining
  Operations               • View Held By Corporate                    Applications Customized
• Subjective Risk                Legal That Knowledge                  For Decision Support
  Assessment                     Management Increases                • Knowledge-based Tax
• Little Understanding           Risk And Liability                    Calculations
  Beyond Legal Issues          • Inconsistent Use Of Peer
                                 Review Process
                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
  Knowledge Management
           For



                                 Best Practice Examples
 Design and Manufacturing


                  Corporate
                 Knowledge
                 Management




         Liability & Risk

 Department of Energy complex developed a liability and
  risk assessment tool for evaluating critical operations and
  determining the correct response.
 Lockheed Martin utilizes a response advisor for determining
  best response to off-normal situations.
 Oak Ridge National Laboratory developed and has
  commercialized a tool for assessing health and safety
  liabilities and risks and providing as assessment of the
  potential impact.



                              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                       The Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Liability & Risk

A knowledge-based, real-time, holistic and
pragmatic view of the enterprise including the
identification, quantification, and mitigation of all
risks/liabilities
        Validated knowledge bases and models that
         accurately quantify risks and liabilities
        Knowledge discovery tools that update the models
        Instant visibility of knowledge-based vulnerability
         assessments

                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                Strategy for Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Liability & Risk


    Provide knowledge enabled risk evaluation
     and mitigation advisors for the identification,
     evaluation, and categorization of risks –
     including advisors for:
       Determination of acceptable risk levels
       Risk mitigation



                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                                     Technology Investment
    Knowledge Management
             For
   Design and Manufacturing




                                              Management
                    Corporate
                   Knowledge
                   Management




           Technology Investment Management

                                                                           Emerging Best
    Lagging Practice                State Of Practice                         Practice
• Inadequate Use Of             • Short Term Outlook                • Certified Vendors
  Knowledge In Capital          • Technology Refresh                • Use Of Knowledge-based
  Budgeting                       Strategies                          Tools Derived From
• Lack Of Long-term Planning    • Technology Roadmapping              Technology Plans And
  For Achievement                                                     Balanced Scorecards
                                • Technology Outsourcing
• Inadequate awareness Of                                           • Value-stream Analysis
  Internal Resources And How                                          Based On Technology
  To Leverage Them                                                    Readiness Levels
                                                                    • Integrated Financial
                                                                      Management



                                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                Best Practice Examples
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Technology Investment Management

   Dow Chemical increased annual licensing income
    from $25 million to more than $125 million in just 5
    years using an Intellectual Asset Management Model
    that reduced patent administration costs and
    identified worthless patents for abandonment.
   Many companies and government agencies are
    moving aggressively to structured technology
    management processes and Technology Readiness
    Assessments as mechanisms for managing
    technology investment.



                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                                       The Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Technology Investment Management

     Optimized technology investment based on the
     alignment with best strategic direction and ROI.
        Dynamic advisors for evaluation of technology options
        Knowledge-based technology investment planning
        Knowledge assisted, objective, technology
         assessment and maturation
        Model-driven technology maturation plans
        Proactive knowledge refresh based on risk and value
         analysis

                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                                Strategy for Vision
Design and Manufacturing


                 Corporate
                Knowledge
                Management




        Technology Investment Management
    Develop a technology selection capability - Provide
     knowledge-based tools to evaluate and select
     technologies and identify voids based on documented
     enterprise needs (technology roadmaps). The tools will
     have the capability to evaluate tactical and strategic
     directions based on opportunity models.
    Provide model-driven maturation plans and decision
     processes to assure the availability of needed
     technology capability.



                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Knowledge Management
          For



                                           Module 5: Summary
Design and Manufacturing


                 Corporate
                Knowledge
                Management




   The current state is characterized by:
           A short focus in managing technology investments
           Widespread use of ERP systems across
            enterprises
   The vision for the future is of a totally integrated,
   knowledge-based capability to make the best business
   and technology choices for all corporate/enterprise
   functions



                             Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
Module 6: Summary and Path
                   Forward




        Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
The Functional Model




Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
            The Workshop Process

For each element of the functional model:
 Developed the current state assessment
 Defined the visions
 Developed the migration plan
 Identified ten key themes for each element
 Prioritized the top 40 themes



                Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                         Top Priority Actions
1. Develop standard knowledge representations
2. Develop an intuitive graphics user interface for
   knowledge management
3. Promote a knowledge management culture
4. Interoperability – seamless exchange of data,
   information and knowledge
5. Explicit use of “life cycle concepts” in the
   management of production data


                    Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                      Top Priority Actions
6. Develop standard mechanisms for knowledge
   capture and management
7. Develop knowledge-based process control
   methodologies
8. Provide knowledge based tools for selecting
   and aligning technology needs with solutions
9. Develop a knowledge base, by sector, that
   captures needed product quality measures
10. Establish automated management of
    knowledge bases
                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                           The Action Topics

   Standard Knowledge Representations
   Intuitive Access to Knowledge
   Life-Cycle Concepts Applied in Processing
   Cultural Acceptance of Knowledge
    Applications




                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Standard Knowledge
     Representations




Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
 Intuitive Access to Knowledge

Provide the ability to capture, retrieve, and
maintain knowledge from the end user
perspective
    Delivery is independent of the
     knowledge systems operation
    Knowledge is managed in real-time
    Knowledge systems adapt and respond
     to users needs


               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
     Life-Cycle Concepts Applied
                   in Processing
Explicit use of life-cycle concepts in Production
Systems
 Today: Life-cycle is applied for product, but seldom
  for process
 Tomorrow: Process capability is managed with the
  product lifecycle
    Product technology refresh is tied to process
     refresh/capability
    Process capability maps to product lifecycle
                 Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
To the Product Centric View . . .




      Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
           Cultural Acceptance of
          Knowledge Applications
The Barriers to Knowledge Applications
Success
  The cost of KM systems
  The lack of standard platforms
  The view that captured knowledge is static
   knowledge
  The Culture that doesn’t embrace
   Knowledge Applications

              Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                  Attributes of Cultural
                            Resistance
 Labor impacts
 Skill mix issues
 Organizational boundaries
 Risks and perceived risks - Lack of a clear
  definition of ROI
 Mindset



                Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                     What Shall We Do?

 Document the business case for knowledge
  applications
 Form a sharing community to work together
  to promote beneficial application
 Establish an infrastructure that supports
  knowledge applications
 Create a forum that owns these and other
  objectives

                Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
                            Closing Comments
 The work shared today is owned by about 60 people who
  gathered in Nashville, Tennessee on October 2003. We
  are honored to present their work.
 All examples used today are from the public domain.
 We thank NASA, NCAM, and Tennessee Tech University
  for their support of this work.
 IMTI is a service organization, and we seek to build on
  this foundation.
 The Next Generation Manufacturing Technologies
  Initiative is a mechanism for doing so.



                     Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         Next Generation Manufacturing
                 Technologies Initiative

 A partnership of ATI, IMTI, and NACFAM
 Funded by the DoD
 Will deliver:
    An industry/government forum
    Technology pilots that address
     manufacturing needs
    A Strategic Investment Plan for U.S.
     Manufacturing

               Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
         A Strategic Investment Plan
              for U.S. Manufacturing
   Emerging Process Technologies
   Model based Design and Manufacturing
   Intelligent Systems
   Enterprise Integration
   Knowledge Management
   Safe, secure, and reliable manufacturing
    operations


                   Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI
We Welcome Your Feedback



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      Knowledge Management for Design & Manufacturing – Copyright NCAM & IMTI

				
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