Application of Digital Manufacturing in Global Automotive ... · Application of Digital...

IJSRD - International Journal for Scientific Research & Development| Vol. 4, Issue 11, 2017 | ISSN (online): 2321-0613

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Application of Digital Manufacturing in Global Automotive Industry: A

Review

Kiran S. Bhokare1 Chandrakant Akhade2 Swapnil S. Kulkarni3 1,2EDS Technologies Pvt Ltd, Pune, India 3Ethika Engineering Solutions India Pvt. Ltd., Pune, India

Abstract— This paper attempts to unfold the possible areas

and functions in an organization where Digital

Manufacturing could have considerable effect on the overall

efficacy of the sub-system and the system as a whole. With

the introduction of Digital Manufacturing over the

conventional setup, the Process Design, Workflow, Plant

Layout, Resource Management and all other such functions

are radically influenced and need to be reviewed in the light

of the changed perspective for achieving production goals.

The role of Information Technology and Communications or

Network Engineering in the IT domain, form a backbone for

this system. At a micro-level, the blending or the integration

of the Mechanical Engineering aspects in the manufacturing

setup with its counterparts in the Electronics and

Communications domain is crucial to exploit the technology

in realizing organizational objectives. The scope and the

possible applications of Digital Manufacturing in

Automotive Industry have been discussed in this treatise.

Key words: Digital Manufacturing, Robotics, Assembly

Simulation, Ergonomics, Process Design, Resource

Utilization

I. INTRODUCTION

Digital manufacturing has been considered, over the last decade, as a highly promising set of technologies for reducing product development times and cost as well as for addressing the need for customization, increased product quality, and faster response to the market. The evolution of information technology systems in manufacturing, outlining their characteristics and the challenges to be addressed in the future needs to be dealt with. Together with the digital manufacturing and factory concepts, the technologies considered here include computer-aided design, engineering, process planning and manufacturing, product data and life-cycle management, simulation and virtual reality, automation, process control, shop floor scheduling, decision support, decision making, manufacturing resource planning, enterprise resource planning, logistics, supply chain management, and e-commerce systems. These technologies are discussed in the context of the digital factory and manufacturing concepts.

II. TODAY’S BUSINESS REQUIREMENTS

Drive Change & Determine Real-time Enterprise Needs

Globalization.

Rapid Product Innovation.

Process Innovation.

Collaboration.

Synchronization.

Lean.

Continuous Improvement.

Compliance.

Risk Management.

Performance.

Flexibility.

Pull-based Production.

Fig. 1: Digital Manufacturing complete Scope

III. EVOLUTION OF THE DESIGN/BUILD PROCESS

Fig. 2: Evolution of Design/Build Process

A. What is Digital Manufacturing?

Digital Manufacturing represents an integrated suite of PLM

tools that supports manufacturing process design, tool

design, plant layout, and visualization through powerful

virtual simulation tools that allow the manufacturing

engineer to validate and optimize the manufacturing

processes. The goal of digital manufacturing is to provide

manufacturers with better insight at critical decision points

to avoid costly errors, gain efficiencies and be able to

respond to customer and market demands in a more agile

manner

Application of Digital Manufacturing in Global Automotive Industry: A Review

(IJSRD/Vol. 4/Issue 11/2017/176)


Fig. 3(a): What is Digital Manufacturing?

Fig. 3(b): What is Digital Manufacturing?

B. Where Digital Manufacturing Fit?

Fig. 4: Where Does Digital Manufacturing Fit in Process?

C. What Does Digital Manufacturing Do?

1) Manufacturing Planning

Define High-Level Manufacturing Processes.

Process Planning (Assembly & Installation).

Define Work Instructions & Work Flow.

2) Detailed Process Design & Analysis

Detailed Resource Modeling & Simulation.

Process Definition and Validation.

3-D Factory Layout.

Equipment, Tool & Fixture Simulation.

Ergonomic Simulation.

3) Validation & Virtual Commissioning

Control Logic Validation.

Kinematic (Robotic) Validation.

Quality Assurance/Process Improvement Validation.

Sensor/Metrology Placement Validation.

Virtual Commissioning/Validation of Automation

Systems.

Knowing that the Production System Works Prior to

Launch: Priceless.

Fig. 5: Virtual V/S Physical World

D. Digital Manufacturing Redefines Concurrent

Engineering

Product Authoring (CAD) tools are employed to define

“What" is to be built.

Manufacturing Process Design tools are used to define

“How" it is to be built.

Integration of Product & Process Design directly

supports the concept of Concurrent Engineering.

Fig. 6: Concurrent Engineering using Digital Mfg.

Digital Manufacturing facilitates the Holistic view

of Product and Process Design as integral components of the

overall product life cycle.

Fig. 7: DELMIA V5 PPR structure

E. Managing the Manufacturing Process

1) PLM/Digital Manufacturing are Process-Centric

Integration of Product Design with Mfg. Processes

allows Production Management & Execution

Applications to be Integrated with the PLM Solution

Set




Manufacturing Process Design coupled with Digital

Mfg. Simulation Integrates the Definitions of the

Product, Processes, Factory, and Resources into a

Comprehensive and Consistent Manufacturing

Solution.

Manufacturing Process Management (MPM), as a

Component of the PLM Solution Set Generates

traditional Operations Management Functions such as

Process Planning, Work Instructions, and Operations &

Quality Assurance Records Scheduling, Workflow,

Resource Management, WIP, and Visibility.

F. Operations Management Definition

Operations Management is the management of the people,

business processes, technology and capital assets involved

in,

Procuring and receiving raw materials and

components.

Implementing product designs, specifications,

formulations, or recipes by manufacturing products.

Distributing these products to customers.

And for some products, supporting them through their

End- of-Life.

G. Production Management Systems are Extension of PLM

Fig. 8: Production Management Systems

H. Merging Virtual Simulation and Automation

Fig. 9: Merging Virtual Simulation with Real World

I. Interoperable Virtual to Real-World Environment for

Manufacturing and Control Engineering

Fig. 10: Control Engineering in Virtual world

J. Digital Mfg. + Shop Floor Execution = Validation of as-

Built to as-Designed

Fig. 11: Digital Mfg. and Shop Floor Execution

K. Merging Virtual Design and Automation Shortens Time

to Launch

Fig. 12: Shorten Time due to Virtual World

L. Applications of Digital Manufacturing

Digital Manufacturing for Optimum Resource

Utilization

Digital Manufacturing for Machining Process.

Digital Manufacturing for Robotics Simulation and

Programming.

Digital Manufacturing for Human Ergonomics and

Analysis (RULA).

Digital Manufacturing for Assembly Process

Simulation and Optimization.

Digital Manufacturing for Operational Intelligence.

Digital Manufacturing for Plant Layout Optimization.




Digital Manufacturing for Product Quality Checking

(CMM).

Digital Manufacturing for Process and Resource Time

Study (MOST & MTM).

Digital Manufacturing for Process Planning.

Digital Manufacturing for 5D Study and Simulation.

Digital Manufacturing for BIW Welding Process.

Digital Manufacturing for Power Train Assembly

Process.

Digital Manufacturing for 3D PLM.

Digital Manufacturing for Material Flow and Logistics.

Digital Manufacturing for PLC Operations.

Digital Manufacturing for Line Balancing and Discrete

Event simulation.

Fig. 13: Applications of Digital Manufacturing

M. Key Benefits of Digital Manufacturing

Integration of Product Design and Manufacturing

Processes.

Reduce Cost and Development Time for Process

Design.

Shorten Time-to-Launch for New Product Introduction

with Faster Ramp-up for Production Systems.

Provide Manufacturability by Simulating

Manufacturing Operations before the Start of

Production.

Increase Quality by Validating Production Process

Design.

Reduce and/or eliminate Prototypes and Physical

Mockups with Virtual Simulations.

Improve Collaboration with Suppliers by Providing

Early Access to Design, Production Process, and

Resource information.

Improve Concurrent Design Methods by Linking

Product Design to Manufacturing & Controls

Engineering.

Validate Manufacturing Processes, Production

Systems, and operational resources through Virtual

Commissioning prior to physical implementation.

N. Scope of Digital Manufacturing for Vehicle

Manufacturing Process

1) Body Shop

Fig. 14a: Body Shop Process Sequence

Fig. 14b: Body Shop Process Sequence

Robots used for Spot Welding and Arc Welding Process

2) Paint Shop

Fig. 15: Paint Shop Process Sequence

Robots used for Painting Process

3) Assembly Shop

Fig. 16: Assembly Shop Application




Robots used for doing the component assembly

process.

4) Engine Plant

Fig. 17: Engine Plant Application

Robots used for Engine Assembly Process

IV. DELMIA SOLUTION CASE STUDY

A. Centerline (Windsor) Limited

Fig. 18: Workcell Robotics Simulation

1) Challenge

CenterLine (Windsor) Limited needed to improve its

robotics manufacturing processes methodology by

implementing standard, collaborative single source- of-truth

technology to provide its customers with on-time, on-budget

and efficient solutions.

2) Solution

The company selected Dassault Systemes3

DEXPERIENCE® platform including DELMIA V6 for

production line design and simulation.

3) Benefits

CenterLine develops more complex manufacturing

installations and makes better use of shop floor space by

visualizing and verifying robot movements in a virtual

environment.

B. Airplane Maintenance Simulation Analysis - Safer and

More Efficient Manufacturing Processes

A leading aircraft manufacturer turned to Applied

Manufacturing Technologies, Inc. (AMT) to use their

simulation and process consulting expertise to identify

issues and recommend solutions for service and

maintenance operations on the manufacturer’s airplanes.

They asked AMT to perform service analyses on four

specific maintenance operations with special consideration

to ergonomic impact. AMT chose to use DELMIA V5

Software to do the analysis. DELMIA, a subsidiary of

Dassault Systemes, offers a comprehensive suite of digital

manufacturing software that streamlines manufacturing

processes to bring products to market faster as well as

lowering manufacturing costs and encouraging innovation.

Fig. 19: Human Reachability study

C. Metris Based Adaptive Robot Control Brings Aerospace

Tolerances to Automotive Robots

Metris has taken part in a major Airbus research project that

results in greater level of automated drilling and riveting

within the aerospace giant. Since industrial robots do not

meet Airbus process specifications, Airbus, Metris, KUKA

and DELMIA partnered to develop a new aerospace grade

robotic platform. This patent-applied-for solution establishes

a dynamic on-line link between a KUKA robot and a Metris

K-series Optical CMM based metrology solution.

Fig. 20: Robotics for Machining Operations

DELMIA simulation of robot cell implementation.

Fig. 21: Robotics for Machining in DELMIA V5

D. Nikon Metrology’s Robot Integrated Laser Scanner

Working closely with Linkoping University and LK

Scandinavia, Nikon developed best practice guides

including optimal approach and angles for laser scanning.

This was used by Chalmers to optimize the measurement

sequence and give base robot program for final verification

in either a robot vender specific simulation system or

generic 3D CAD based simulation system (using Realistic

Robot Simulation technology).




Fig. 22: Robot Programming and simulation

In this project both ABB’s Robot Studio and

Dassault’s DELMIA V5 were successfully used, providing a

simple method of creating robot programs and proving them

off-line.

Fig. 23: Relealistic Robot Programming and simulation

using DELMIA V5

E. Holland Project: Digital Reconstruction of Naval

History

Digital Simulation: - Kinematics models were developed for

mechanisms such as the access hatch and latching

mechanism, inner and outer torpedo tube doors, gasoline

engine, pumps, and electric motor/ generator. In each case,

the kinematics mechanism was used to validate the design

and to provide insight into the operation of the submarine.

The combination of Part Design, Assembly design

and Kinematics produced a complete physical model, but

how did it really work? What were the steps involved in

getting underway, diving the boat, firing a torpedo, and

conducting routine maintenance?

F. DELMIA’s Digital Process for Manufacturing

(DPM) provided many of the tools needed to answer these

questions. DPM was used to simulate the operation of all

equipment onboard the USS Holland, including submerging

and torpedo launching and reloading.

Fig. 24: DELMIA V5 in Submarine and Torpedo launching

Mechanical simulations are great, but in a

submarine such as the USS Holland where space is limited,

it was important to determine how long it would take for a

man to get into position to close a valve, pull a lever or flip a

switch. DELMIA’s Human Task Simulation was used to

explore these areas.

REFERENCES

[1] Mr. Atmaram D.Naik, Prof.M.V.Sulakhe,

Prof.S.G.Dhande, “Digital Manufacturing for

Automotive Suppliers” Proceedings of International

Conference on Advances in Machine Design & Industry

Automation, January10-12. 2007.

[2] Engelbert Westkamper, Digital Manufacturing in the

global Era, Fraunhofer Institute IPA University

Stuttgart, Germany.

[3] Digital Solutions,

http://www.3ds.com/products-services/ delmia/

[4] G Chryssolouris, D Mavrikios, N Papakostas, D

Mourtzis, G Michalos, and K Georgoulias, “Digital

Manufacturing: History, Perspectives, and Outlook”,

Proc. IMechE Vol. 223 Part B: J. Engineering

Manufacture.

[5] WMG DIGITAL, “Digital Manufacturing,

Technologies and Healthcare”, The University of

Warwick.

[6] Capgemini Consulting, “Operational Excellence

through Digital in Manufacturing Industries”

http://www.capgemini-consulting.com/

[7] ARC Advisory group, Integrating PLM with the Shop

Floor: Validating As-Built to As-Designed.

[8] ServiceTrace Partner, CENIT AG, “Automated

Testing”

[9] Contact Mag, “The V5 PLM Magazine” 2007.

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