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IJSRD - International Journal for Scientific Research & Development| Vol. 4, Issue 11, 2017 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 675
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)
All rights reserved by www.ijsrd.com 676
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
Application of Digital Manufacturing in Global Automotive Industry: A Review
(IJSRD/Vol. 4/Issue 11/2017/176)
All rights reserved by www.ijsrd.com 677
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.
Application of Digital Manufacturing in Global Automotive Industry: A Review
(IJSRD/Vol. 4/Issue 11/2017/176)
All rights reserved by www.ijsrd.com 678
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
Application of Digital Manufacturing in Global Automotive Industry: A Review
(IJSRD/Vol. 4/Issue 11/2017/176)
All rights reserved by www.ijsrd.com 679
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).
Application of Digital Manufacturing in Global Automotive Industry: A Review
(IJSRD/Vol. 4/Issue 11/2017/176)
All rights reserved by www.ijsrd.com 680
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.