How DELMIA solutions facilitate data flow in a Digital Factory

What is a Digital Factory?

A Digital Factory represents a virtual model of the real-world production process. It integrates various systems and technologies to streamline production planning and scheduling, product design and development, and manufacturing execution. The core purpose is to link different production phases, ensuring that data flows smoothly across each stage, helping manufacturers increase control of workflows, enhance productivity, and minimize errors. Consequently, a Digital Factory enables enterprises to effectively reduce time to market while gaining a competitive advantage.

The role of CAD, PDM, and PLM systems in product development

Before the actual production can begin, manufacturers need to leverage the right solutions for effective product design, planning, and development. Systems like Computer-Aided Design (CAD), Product Data Management (PDM), and Product Lifecycle Management (PLM) play crucial roles in this phase.

CAD systems are essential tools in the product development phase, enabling engineers and designers to create precise 2D and 3D models of products and equipment. CAD goes beyond basic drawing capabilities, enabling users to simulate real-world conditions, test functionalities, and optimize designs before the actual production begins. CAD-generated models contain detailed geometrical, material, and structural data that are integrated directly into manufacturing systems, thus facilitating cross-team collaboration and ensuring that production is aligned with the initial design intent.

PDM systems focus on managing, monitoring, and tracking all the data related to the product design and engineering phase. PDM stores and organizes key design files such as 3D models, drawings, and technical documentation. More specifically, PDM systems handle the Engineering Bill of Materials (EBOM), which includes all the parts, components, and elements required to assemble the final product. The data provided by PDM and flowing into the Digital Factory is crucial for ensuring the smooth and efficient transition from the design stage to active product manufacturing.

PLM systems provide a more comprehensive approach, overseeing the entire lifecycle of a product—from initial concept through design, production, and eventually, disposal. In addition to managing the EBOM, PLM systems integrate product data with key business processes, ensuring swift collaboration across teams and departments. This interconnected and holistic view of production planning and resource management helps manufacturers optimize product development cycles, manage changes efficiently, and maintain quality control throughout the entire product's lifecycle.

Data flows from development to production

Once the product development phase is complete, the data flows into the Digital Factory for production planning. This involves transferring 3D models and EBOM data into systems such as the Manufacturing Bill of Materials (MBOM) and routings, which control and manage the operational aspects of production like work instructions and machine programs. Ensuring a smooth and effective data flow is essential for shop-floor operators to know exactly what to do and when.

Key systems in the Digital Factory’s production process

The transition from digital planning to physical production involves the integration of three key manufacturing solutions, namely Enterprise Resource Planning (ERP), Advanced Planning & Scheduling (APS), and Manufacturing Execution Systems (MES).

ERP

ERP systems handle orders, track inventory, manage resources, and issue MBOM and routing instructions. They ensure that all the required materials and resources are in place, aligning production capacity with customer demand.

APS

APS handles the planning and scheduling of production orders, ensuring that resources are allocated efficiently and that production runs smoothly. It optimizes schedules based on real-time demand, making the manufacturing process as efficient as possible.

MES

MES bridges the gap between ERP and the shop floor. It converts MBOM data into actionable work instructions and machine programs for operators and shop-floor equipment. Additionally, it provides real-time insights into production processes, allowing for immediate adjustments.

Feedback loops and optimization

In a fully Digital Factory, where data flows in both directions between the systems, feedback loops are critical.

Production feedback is sent from MES to ERP, helping refine future orders and planning.

Machine feedback is also sent from the shop floor to MES, facilitating the optimization of production processes to drive continuous improvement.

This continuous data loop ensures agility and responsiveness to changes in production demands, equipment status, and supply chain issues.

The Digital Factory can help you gain a competitive edge

The Digital Factory represents the pinnacle of innovative and paperless manufacturing, where data flows seamlessly between systems, from initial product design to final production. By integrating vital manufacturing systems, like CAD, PDM, PLM, ERP, APS, and MES, you can optimize production, reduce waste, and enhance agility. The Digital Factory facilitates an interconnected data flow, enabling you to respond quickly to market demands, reduce downtime, and ultimately drive better business outcomes that lead to a greater competitive edge in your industry.

DELMIA solutions as pillars of your Digital Factory

Take the first step towards digitalizing your manufacturing operations. Explore how DELMIA solutions can become the foundation for your entire Digital Factory. Learn how DELMIA Ortems APS can help you with advanced planning and scheduling of your production while DELMIA Apriso MES will increase your control across the entire manufacturing environment.

Having worked with over 80 global manufacturers gives Andea an edge no other manufacturing, engineering, and planning solutions integrator or reseller can match—an industry-wide understanding of even the most complex production processes. This extensive industry experience, combined with our exhaustive knowledge and proven track record of implementing MES and APS systems, enables our experts to lead you toward manufacturing excellence.

Visit our case study section to learn how we’ve helped top manufacturers gain a competitive advantage.

Understanding data flows and systems in a Digital Factory