IJSRD - International Journal for Scientific Research & Development Vol. 4, Issue 11, 2017 ISSN (online): 2321-0613 Application of Digital Manufacturing in Global Automotive Industry: A Review Kiran S. Bhokare 1 Chandrakant Akhade 2 Swapnil S. Kulkarni 3 1,2 EDS Technologies Pvt Ltd, Pune, India 3 Ethika 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 Fig. 1: Digital Manufacturing complete Scope 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 lifecycle 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. 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 All rights reserved by www.ijsrd.com 675
Virtual Commissioning/Validation of Automation Systems. Knowing that the Production System Works Prior to Launch: Priceless. Fig. 3(a): What is Digital Manufacturing? Fig. 3(b): What is Digital Manufacturing? B. Where Digital Manufacturing Fit? 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. 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. 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 All rights reserved by www.ijsrd.com 676
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 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. 8: Production Management Systems H. Merging Virtual Simulation and Automation Fig. 12: Shorten Time due to Virtual World Fig. 9: Merging Virtual Simulation with Real 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. All rights reserved by www.ijsrd.com 677
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. Application of Digital Manufacturing in Global Automotive Industry: A Review N. Scope of Digital Manufacturing for Vehicle Manufacturing Process 1) Body Shop Fig. 14a: Body Shop Process Sequence 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. 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 All rights reserved by www.ijsrd.com 678
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. 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. 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. 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). All rights reserved by www.ijsrd.com 679
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. All rights reserved by www.ijsrd.com 680