| NISTIR 5839 | |
Systems Integration for Manufacturing Applications Program 1995 Annual Report | |
| James E. Fowler | |
| Mark E. Luce | |
| U.S. DEPARTMENT OF COMMERCE Technology Administration National Insitute of Standards and Technology Maufacturing Engineering Laboratory Manufacturing Systems Integration Division Gaithersburg, MD 20899 | |
| May 1996 | |
| U.S. DEPARTMENT OF COMMERCE Michael Kantor, Secretary TECHNOLOGY ADMINISTRATION Mary l. Good, Under Secretary for Technology NATIONAL INSTITUTE OF STADARDS AND TECHNOLOGY Arati Prabhakar, Director | |
An intramural NIST research and standards development program applying High Performance Computing and Communications technology to manufacturing applications.
Program Office Staff
The SIMA Program Office is responsible for managing and compiling information for all projects supported by the SIMA program. The SIMA program office staff are:
This publication was prepared by United States Government employees as part of their official duties and is, therefore, a work of the U.S. Government and not subject to copyright.
The systems integration requirements of U.S. manufacturing firms can best be captured by close interaction with industry representatives possessing first hand experience in addressing the integration problems of software systems supporting manufacturing activities. SIMA is guided by these interactions to set priorities supporting U.S. industries. These interactions have included both conferences and workshops convened by NIST before and after the SIMA Program was initiated. Based on the industry input received, the SIMA Program consolidated its efforts into three major program categories and prioritized the focus of each so that each addresses requirements as defined by industry. The three major categories defined for SIMA support of manufacturing systems integration were: (1) technology development, (2) standards development, and (3) testbeds and technology transfer. These three categories are reflected in the organization of SIMA technical activities into three program areas: (1) Manufacturing Systems Environment, (2) Standards Development Environment, and (3) Testbeds and Technology Transfer Environment.
The SIMA Program is directed by a manager who is located in the Manufacturing Systems Integration Division (MSID) of NIST's Manufacturing Engineering Laboratory (MEL). The Program Manager oversees the SIMA technical projects which are carried out by staff from all of NIST's laboratories. SIMA projects must satisfy certain criteria. Projects are aimed at providing a "standards solution" for manufacturing systems integration while applying HPCC technology. In particular, each project must:
The majority of the projects in MSE address different aspects of the discrete mechanical parts lifecycle. The Design Applications project investigated data requirements for the representation, manipulation, visualization, and planning of assemblies with Caterpillar. The Modeling of Manufacturing Resources project developed a data model for machine and cutting tools in conjunction with members of the Rapid Response Manufacturing consortium. The Process Planning Applications project developed models for process planning and leveraged this work for development of pilot implementation of a proposed international standard with the Institute of Advanced Manufacturing Sciences. The Production Applications project focussed on the interfaces between production, scheduling, and simulation systems and produced a simulated production system based on work with Black & Decker.
Two other MSE projects focus on the discrete parts manufacturing domain from the simulation perspective. The Operator Interfaces for Virtual and Distributed Manufacturing project addressed the human-computer interface issues for remote control and monitoring interactions. The project successfully demonstrated a prototype graphical interface to a simulated gear factory in conjunction with Advanced Technology Research Corporation. The Virtual Reality for Manufacturing project investigated the applicability of virtual reality technologies to a manufacturing environment and has established simulations of product assembly lines in conjunction with Black & Decker.
MSE projects also cover the manufacturing domains of plant construction, custom footwear production, and electronic system design. The Process Plant Engineering and Construction project investigated the emerging international protocols for steelwork specification in light of U.S. requirements with the American Institute of Steel Construction. The STEP for the Process Plant Industries project worked in the development and validation of data exchange protocols supporting the design of process plants; the project helped establish the PlantSTEP consortium for testing of these proposed standards. The Virtual Enterprise Frameworks for Small Manufacturers project investigated the interface protocol issues relating to the integration of processes supporting the design and production of custom footwear. The Electronic Commerce for the Electronics Industry project worked to develop the protocols needed for electronic component design data access in conjunction with SEMATECH.
In the Standards Development Environment there are three projects. The Application Protocol Development Environment project worked on an integrated suite of software tools expediting the creation of international standard data exchange protocols. The project worked with Concurrent Technologies Corporation for testing of remote collaborative mechanisms. The STEP Conformance Testing project worked to establish the testing methodologies and software tools which will ensure that data exchange protocols conform to the international standards. The project worked with the PDES, Inc. consortium on validation of the testing tools in the consortium's pilot implementation projects. The STEP Implementations project worked to establish mechanisms facilitating implementation of STEP data exchange protocols in practice through participation in the Automotive Industry Action Group Supply Chain Integration effort and the U.S. Army's Defense Systems Supply Chain Integration effort.
In the Testbeds and Technology Transfer Environment there are five projects. The Advanced Manufacturing Systems and Networking Testbed (AMSANT) project established a facility for use by all SIMA projects providing them with high-performance scientific workstations and high-speed networking capabilities. The facility's networking capabilities has been put to use for remote access to Sandia Laboratory for establishment of a virtual, collaborative manufacturing engineering prototype. The AMSANT for Process Plant Industries project provided a distributed link to the primary AMSANT facility and specifically provides capabilities supporting the process plant projects. The Analysis Tools for Assessment and Optimization of Process and Product Design project worked to establish an on-line environment providing engineers with access to statistical tools fundamental to design and manufacturing processes. The project worked closely with SEMATECH to define the capabilities needed. The Manufacturing Information Technology Transfer project worked to provide the internet infrastructure tools necessary to support SIMA project technical activities as well as to disseminate project information. The Standard Reference Data Delivery and Use project worked to make NIST databases of evaluated scientific data accessible through the internet to manufacturers developing new products and processes.
The SIMA Program is managed to ensure that the technical activities of the program address the requirements of U.S. industry, are appropriate to the mission of the NIST Laboratories, and are consistent with the overall HPCC/IITA goals. NIST's unique focus on working with industry to develop voluntary, consensus standards will be a key feature of SIMA projects as their technology developments mature. In FY96 the SIMA Program will be instituting a process that responds to the need for activities leading to the development of standards at a more rapid pace.
Initial Manufacturing Exchange Specifications (IMES's) are protocols that will cover interfaces between manufacturing applications, interfaces between manufacturing applications and manufacturing data repositories, and interfaces between users and the applications themselves. Industry participation throughout the IMES development process will ensure that the IMES satisfies the intended requirements with a viable solution. This formal IMES development process should ensure that the resulting specifications are high quality, industry-tested solutions ready for the voluntary standardization process.
This report provides an overview of the program, describes the technical projects comprising the program, and highlights key accomplishments for each project. In addition, the appendices provide a detailed listing of project collaborators, as well as a listing of project publications and other available project resources. The intended audience for this document includes NIST staff working on SIMA-supported projects, private sector organizations collaborating with NIST, government agencies supporting the government initiative on High Performance Computing and Communications (HPCC), and the general public. This report is available via the SIMA external home page (http://elib.cme.nist.gov/msid/projs/sima-pm/sima.htm) or by electronic mail request to the SIMA Program office secretary (blthomas@cme.nist.gov).
The SIMA Program is focussing on technologies and standards that can improve manufacturing systems integration. The program involves all seven NIST laboratories and emphasizes both product and process data exchange for manufacturing in conjunction with electronic data interchange for electronic commerce. Through FY95, the SIMA effort has developed, tested, validated, and demonstrated multiple integration approaches for manufacturing software applications supporting design, planning, and production. Frameworks and industry-accepted integration methodologies guide the selection of integration approaches. Integration tools used include state-of-the-art commercial software, pre-commercial software, and prototype software as necessary. Combining these integration approaches with network communication infrastructure technologies will advance the state-of-the-practice in industry towards modular, open, reconfigurable, and intelligent manufacturing systems.
The SIMA Program is built upon the premise that standards are necessary to integrate manufacturing systems and that the availability of the NII accelerates the need for voluntary industry standards. ISO 10303, commonly known as the Standard for Exchange of Product Model Data or STEP [5], is considered to be a key standard for integration efforts. STEP is expected to accelerate the evolution of concurrent engineering, support electronic data interchange and electronic commerce, and enable business partners to share sophisticated product data representations throughout the product lifecycle. As such, STEP promises to be one of the most influential standards that has ever been developed in the industrial automation field.
A workshop entitled "System Integration Needs of U.S. Manufacturers" was held at NIST in 1993 to identify the key systems integration needs of U.S. manufacturers in the areas of technology development, standards development, and technology transfer [6]. These needs were defined in terms of the objectives set forth for NIST by the advanced manufacturing application focus planned for the IITA component of HPCC. The results of that workshop have been used to define the role of the SIMA program with respect to the requirements of U.S. industry and to help identify mechanisms by which NIST can respond to industry priorities.
A second workshop entitled "SIMA Interactive Management Workshop" was held at the Defense Systems Management College in November 1994 [7]. The workshop brought together representatives from industry and government programs in the area of manufacturing systems integration resulting in the definition of actions for the SIMA Program and the identification of leveraging opportunities between SIMA and other government and/or industry programs. Another result of that workshop was identification of opportunities for collaboration between programs to maximize the resources being applied to system integration.
In addition to the focused workshops described above, SIMA sponsored a background study of industry requirements in the area of manufacturing systems integration [8]. The study assessed integration requirements for design, planning, and production software applications that support manufacturing. Existing technologies and emerging standards were reviewed to identify technical obstacles faced by industry in developing integrated manufacturing systems. The results of this study provide an understanding of the scope of integration problems related to the design, planning and production of mechanical products. The background study provides a useful overview of why SIMA is focusing on integration problems and establishes a baseline for SIMA efforts in manufacturing systems integration. Additionally, the report provides a rationale for developing collaborative efforts among NIST, industry, other government agencies, research organizations, and standards bodies.
The SIMA Program is one of five that has been created at NIST in response to the HPCC initiative (see Figure 1). The SIMA Program is directed by a manager in the Manufacturing Systems Integration Division (MSID) of NIST's Manufacturing Engineering Laboratory (MEL). In addition to overseeing the SIMA Program, the SIMA Program office manages selected external relationships with other agency programs supporting the HPCC initiative, serves as liaison to the HPCC Information Technology committee, and assists with long-range planning and program support for NIST laboratories participating in the program. The program manager is responsible for:
Manufacturing Systems Environment (MSE)
The objectives of this environment are to develop integration technologies and standards in support of a broad range of industrial manufacturing domains that include mechanical products, apparel, electronics, construction, and chemical processing. The application systems of interest within these domains include design (product, process, and enterprise), planning, scheduling, process modeling, shop control, simulation, inspection, assembly, and machining. The problem scope includes manufacturing systems integration both within and among multiple enterprises. The MSE projects focus on the development of infrastructure technologies, interface protocols, and information models with the intention of applying these integration solutions to application system incompatibilities. Typical integration and interface technology solutions include network communications, information protocols for product and process data, database technologies, and frameworks. The major result of MSE activities are integration specifications for manufacturing systems and prototype process models for use throughout the manufacturing environment. Standards Development Environment (SDE)
The objectives of this environment are to assist industry in implementing voluntary consensus standards relevant to computer integrated manufacturing (CIM), facilitate industry efforts to test new applications of advanced manufacturing systems and networks, facilitate efforts to develop and test new data exchange standards utilizing HPCC technology, and accelerate industry deployment of consensus standards. There is a general theme of providing effective support environments for the development of standards as well as facilitating the harmonization across the broad spectrum of standards that compose the range of information and supporting technology required for enterprise integration. Several projects will be involved in coordinating the support mechanisms and information across the various industries. Testbeds and Technology Transfer Environment (TTTE)
The objectives of this environment are to develop technology transfer infrastructure which can be used to exchange manufacturing information using HPCC technology, to develop prototype information services in collaboration with industry partners which could become commercialized products, to develop services related to document searches and retrieval of government and other research reports, and to establish communication channels for network of researchers and implementors of manufacturing technologies. Testbeds developed under the auspices of TTTE are intended to serve as demonstration sites that industrial technology suppliers and users can utilize, to serve as the interfaces to a network of technology development testbeds across the United States, and to serve as the focal points for information dissemination. Program Operation
Planning is a key aspect of the SIMA Program. The primary purpose of this planning is to help ensure that the program remains responsive to industry needs and applies HPCC technology to support these needs. The SIMA Program uses a planning process to:
Overall guidance for the program is provided by a management council consisting of the program manager and one Division Chief from each participating NIST laboratory. Individual SIMA projects are led by research staff from the participating laboratories and directed by the SIMA Program manager. The following sections briefly summarize the respective missions of each NIST laboratory participating in the SIMA Program2.
Telephone: (301) 975 - 6550
This project is addressing integration and information exchange issues associated with design engineering, interoperation, and the modeling of engineering processes. Specifically, the project focuses efforts in the following four areas:
Telephone: (301) 975 - 4124
This project is providing mechanisms for access to electronic component design data at various points in the design flow through development of formats and protocols for exchange of product component information. Specifically the project is focussing on:
Telephone: (301) 975 - 3888
The U.S. manufacturing industry is strengthening customer-supplier relationships at the systems level and is supporting these relationships by integrating distributed manufacturing systems. The SIMA Integration project is working with three national consortia as well as with other NIST projects to develop integration standards for distributed manufacturing software systems. The basis for these standards are models of manufacturing-related information and corresponding protocols for exchange. These models and protocols are critical to defining and designing the interfaces between software applications. Well defined interfaces are critical to reducing the cost of creating distributed manufacturing software systems. These models, protocols, and standards will be of particular use to system integrators and software providers building systems that support product design, manufacturing engineering, and production engineering activities.
Telephone: (301) 975 - 5486
Telephone: (301) 975 - 3460 E-mail: kent@cme.nist.gov
The objective of this project is to understand and address standards issues in human interfaces for virtual and distributed manufacturing systems employing HPCC technology. The project is developing methods to collect and present relevant manufacturing information at an appropriate level of abstraction for interactively examining remote operations and representations, and cooperatively controlling remote systems.
The issue addressed is that of human interfaces for control of distributed and simulated manufacturing systems, as developed in a laboratory setting for the SIMA AMSANT facility. The focus is not only on remote interaction with shop-floor equipment, but also on interfaces for development, management and control of plant, operations, processes, and design at a variety of levels such as shop-floor supervisor, production foreman, plant manager, production executives, facility designers, product designers, process designers, and consultants. The general problem is to collect and present the relevant information, at the appropriate level of detail, and in the most efficient possible format, to a variety of remote decision-makers and allow them to examine interactively remote situations and cooperatively control the remote environments. Issues with which the project is concerned are:
Telephone: (301) 975 - 3524 E-mail: ray@cme.nist.gov
The objective of this project is to improve the capabilities and integration of manufacturing planning applications. This is being addressed in three ways: (1) specifying a series of information and process models and communications protocols needed by manufacturing planning systems, (2) implementing these specifications as part of an integration activity using commercial planning system software, and (3) developing a repository of information supporting the research, development, and integration of future planning system applications. The information shared between the planning functions and other engineering functions such as design, scheduling, and production is being identified, formally modeled, and implemented as a series of databases. Access to these databases will be via accepted or emerging standard mechanisms.
Telephone: (301) 975 - 5852

The object of this project is to work with U.S. industry to develop its technical capability to represent and exchange information supporting the design and construction of structural systems using internationally accepted protocols. ISO TC 184/SC 4 has recently embarked on a STEP application protocol project that addresses structural steelwork, based on European input from the Eureka CIMSteel project. NIST is working with U.S. industry members and the cognizant professional society, the American Institute of Steel Construction (AISC), to ensure that this STEP project properly addresses U.S. requirements. NIST is exploring the potential use of STEP application protocols to create virtual construction environments that allow engineers and constructors to visualize and manipulate a common process plant model from widely disparate viewpoints.
Telephone: (301) 975 - 3511
This project is addressing integration problems associated with production engineering, scheduling, and simulation systems. The project is developing process models, information models, and interface specifications, databases, and extensions to commercial production software that resolve or facilitate system integration. After assessing industry needs, this project has selected and installed software applications that are used to engineer a production system, perform production scheduling, and simulate production. Prototype integrated systems are being constructed from commercial products and industry provided data. The principal elements of the technical approach are to:
Telephone: (301) 975 - 3437
E-mail: scott@cme.nist.gov

The objective of this project is to develop a detailed design of a reference model architecture for intelligent control of manufacturing processes and to demonstrate, validate and evaluate the NIST Reference Model Architecture through analysis and performance measurements of a simulated and prototype implementation. The approach includes leveraging the work of other programs, such as the NIST Enhanced Machine Controller, in developing interface specifications among the architectural components, and working with industry in developing tools to support development of Reference Model Architecture based system implementations. The goals of this work are to provide U.S. industry with state-of-the-art manufacturing architectures and models, foster the development and implementation of advanced manufacturing systems, and anticipate and address the needs of the U.S. manufacturing industry for the next generation of advanced systems and standards.
Telephone: (301) 975 - 5858
This project is working with industry to develop, test and demonstrate the STEP application protocols needed for exchanging and sharing information during the design, construction, operations, and maintenance of process plants. The objectives of this project are:
Telephone: (301) 975 - 3548
E-mail: moncarz@cme.nist.gov

In this project, NIST researchers are developing a virtual enterprise framework in collaboration with the custom therapeutic footwear (CTF) industry. The framework will be used to develop interoperability standards needed by the industry to integrate the manufacturing processes required. The effort will enable the CTF industry to enjoy the benefits from open, modular, and reconfigurable integration of commercial software applications that support the design, planning, and production of products within the SIMA vision of a virtual manufacturing enterprise. Project collaborators comprise a broad set of domain experts, including medical researchers who are studying foot problems and treatment with CTF, manufacturing technologists who are developing new manufacturing technologies (e.g., automated foot measurement devices, new CTF CAD systems, etc.), and the CTF manufacturers themselves to deploy and test the new technologies in an actual business scenario.
Telephone: (301) 975 - 3549
The objective of this project is to explore the use of virtual reality (VR) technology to assist the manufacturing industry in achieving systems integration of manufacturing applications. This is being done by enhancing several SIMA applications through VR technology. Current limitations of VR technology are being scrutinized, different ways to make the technology more efficient are being explored, and VR standards which will enhance the manufacturing process are being investigated. VR is usually defined as a computer-generated simulation of a three dimensional environment, in which the user is both able to view and manipulate the contents of that environment, gather information, and effectively solve problems.
Telephone: (301) 975 - 3287
E-mail: mitchell@cme.nist.gov

The APDE project is accelerating the development of STEP and aiding application protocol (AP) developers in creating STEP specifications more efficiently, with high quality and at a lower cost, by establishing an integrated suite of software tools. Application protocols submitted to ISO must meet specified criteria for standardization and usually require extensive rework before they are allowed to progress through the standards process. Current practices used for AP development require extraordinary labor expenditures on behalf of AP developers to define AP documents. While AP developers may use some software tools to help them accomplish their AP development tasks, the tools work independently, are not integrated, and have not been customized specifically for the purpose of AP development.
The software tools being developed in the APDE project are integrated and they interact with a central information repository at NIST. The repository consists of STEP-related documents and data, much of it represented in Standard Generalized Markup Language (SGML). As the project matures, collaboration with various software suppliers will be established. The APDE goal is 40% reduction of the AP development cycle time, currently estimated at 2-4 years with 4-6 full time equivalent staff.
Telephone: (301) 975 - 3287
E-mail: mitchell@cme.nist.gov

This project is providing the means by which vendor's software products will be measured for conformance to the STEP standard, through development of a set of value added software tools that will be made available for vendors to use during their product development process. Under this approach, vendors gain confidence that their products can successfully pass testing, vendors have access to tools that improve the quality of their products and reduce the costs of software testing, and vendors gain in the expanded market that user confidence in testing brings.
Telephone: (301) 975 - 3287
This project is accelerating the adoption of STEP by promoting development of industry consensus on implementation and facilitating implementation of production-ready STEP applications. NIST is working with industry to identify requirements for interoperable systems by providing guidance on implementing STEP within a well defined scope, by developing test methodologies and data exchange metrics, and by testing STEP translators within the context of industrial pilots. NIST is working to ensure implementation experience is fed back into the standards process. The goal is to achieve the introduction of STEP into production environments. The project is collaborating with the AutoSTEP pilot which includes participants from Ford, General Motors, Chrysler and their suppliers. NIST has interviewed industry collaborators to obtain information on requirements and infrastructure data. This project has established and will maintain an on-line database of STEP translator problems. Project collaborators will log the results of each STEP data transfer. CAD system vendors will use this data to identify and fix problems in subsequent software releases. The project aims to ensure that STEP is responsive to the product data needs of U.S. industry.
Telephone: (301) 975 - 6546
E-mail: densock@cme.nist.gov

The Advanced Manufacturing Systems and Networking Testbed (AMSANT) facility houses special purpose, high-performance computers equipped with high speed networking (Asynchronous Transfer Mode - ATM) capabilities that are being used by NIST researchers and external collaborators to develop new manufacturing technologies and standards, as well as demonstrate proof-of-concept solutions to manufacturing systems integration problems. MEL is teamed with NIST's Computing and Applied Mathematics Laboratory and Computer Systems Laboratory to pioneer an ATM backbone network at NIST and to connect NIST to the ATDnet. The ATDnet is a Washington area ATM test network that connects several government agencies performing research on the NII.
Telephone: (301) 975 - 5852
The objective of this project is to establish an experimental computing and communication facility to:
Telephone: (301) 975 - 2855
The objective of this project is to develop an integrated computer environment which provides a design/manufacturing engineer immediate on-line access to those statistical analysis tools necessary for characterizing, modeling, monitoring, and optimizing a process or product. This is achieved by creating an engineering-friendly, integrated system with the following capabilities:
Telephone: (301) 975 - 3537
This project is providing a coordinated and focused infrastructure of the emerging tools, technologies and growing electronic networks that have resulted from the information exchange revolution currently underway across the NII. These systems will enable American industry to have access to readily-available information bases containing up-to-date manufacturing research developments and practices and to facilitate information sharing and collaboration opportunities. To date, MITT's efforts have concentrated on building an infrastructure of available tools and servers for information dissemination and populating a manufacturing resource repository. In FY94 MITT efforts included the development of an on-line prototype suite of authoring, searching and retrieval tools and a core set of selected information bases on-line, that were identified in a needs analysis conducted in FY94. In the second year the project has focussed on teaming with other SIMA projects to apply these tools and services to improve communication and technology transfer of results to the manufacturing standards communities.
Telephone: (301) 975 - 2213
Project Manager: Gary Kramer
Telephone: (301) 975 - 4132
E-mail: gary.kramer@nist.gov
Project Manager: Gary Mallard
Telephone: (301) 975 - 2564
E-mail: gary.mallard@nist.gov
Project Manager: Edward Saloman
Telephone: (301) 975 - 5554
E-mail: edward.saloman@nist.gov
Critical decisions in manufacturing and engineering depend on reliable data. The NIST Standard Reference Data Program (SRDP) provides numeric data critically evaluated in data centers throughout the NIST laboratories. The thrust of this project is to make that data more readily available to engineers and scientists in U.S. industry. The breadth of the NIST data program and the diverse expectations of the industrial community require that NIST provide tools to help users find the data they need. Much of the NIST data is available today with responsive interfaces for individuals to use on their local computers. Project participants are creating ways to reuse the existing structures and algorithms, generating new algorithms where necessary, in order to deliver the existing and future NIST data, so that the data are both accessible on-line to individuals and freely exchangeable among instruments. SIMA efforts are taking place in two NIST laboratories, the Chemical Science and Technology Laboratory and the Physics Laboratory, with coordination and supporting activities performed by SRDP. The chemistry projects began in FY94. The physics lab began participating in FY95.
In response to this need, in FY96 the SIMA Program will develop a structured process for technical projects to follow in their development of protocols for data exchange. These protocols, which will be known as Initial Manufacturing Exchange Specifications (IMES), will cover interfaces between manufacturing applications, interfaces between manufacturing applications and manufacturing data repositories, and interfaces between users and the applications themselves. The overall IMES development process will be a phased approach, with the expectation that the timeframe from start to finish would be 2 to 3 years. Phases for IMES development will include industry requirements analysis, specification development, prototype implementation and validation, and initiation of the standardization process. Industry participation throughout the IMES development process is expected to ensure that the IMES satisfies the intended needs with a viable solution. This formal IMES development process should ensure that the resulting specifications are high quality, industry-tested solutions ready for the voluntary standardization process.
Appendix B: FY94 and FY95 Project Publications
MSE1: Design Applications, (p. 11)