Virtual manufacturing

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Virtual manufacturing

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December 17th_{, 2001}

I nt e gra t e d M a nufa c t uring T e c hnologie s I nst it ut e

Virtual Manufacturing

Sha fe e Aha m e d Re se a rc h Offic e r

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Agenda

:

What is Virtual Manufacturing

Paradigms in Virtual Manufacturing

Core elements in Production-Centered VM Virtual Plant model in context to applications Details of core elements in PC-VM

Simulation scenarios building IMTI’s R&D program

Benefits and Challenges

What does Technology say What can be done presently What are requirements Seeing is believing What can IMTI do to GMD

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What is Virtual Manufacturing ?

Is the use of computer models and simulations of products and processes to aid in the design and production of

manufactured products with various levels of decision and control

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Paradigms in Virtual Manufacturing Design-centered VM Direct Approach Evaluation Approach Production--centered VM Distributed Manufacturing Production Flow CIM,FMS MRP, ERP, SAP STEP –NC STEP 214, 224 Technology PLC, CAM Planning & Scheduling, DES DFM, DFA, D2M

CAD based sim Areas

Interactions & Information Production

Environments Shape Attributes &

Feature based Focus Control-centered VM M/c, Cell based Network based

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Mo

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lin

g

DE

_S

V

is

u

a

liz

a

tion

Humans

C

&

C

VIRTUAL

MANUFACTURING

Production-Centered

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Virtual Plant Model

(Production Application)

What can we do:

• Production Throughput • Work In Progress • What if • Identify Bottlenecks • Flow Analysis • Capacity Analysis

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Virtual Plant Model

(Ergonomics Application)

What can we do:

• Posture analysis

• Strength and energy requirements

• Comfort and health issues

• Reachability analysis

• Achievability analysis

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Plant Simulation

Symbols / Icons (2D) Objects (3D) Labor Transportation Paths

Modeling

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Plant Simulation

Populating objects and labor Shifts, schedules and failures

Logics (process, route, controller..) ASRS

Discrete Event Simulation

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Plant Simulation

2 way link

Adaptive control Product tracking

Integration with MRP/ERP & Scheduling systems

Control and Communications

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Plant Simulation

CAD interfaces

Dynamic interferences

Collaborative and web access

Reporting capabilities

General Capabilities

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Simulation case

- Maximize the final product with NO bottleneck.

Assumptions: The machine time and flow rate of MHS cannot be changed

Problem:

- JIT concept, Inventory should be minimum

- Identify the best arrival rate of raw material A

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Simulation methodology

15 25 10 Bottleneck where Part C Count Part B Count Part A Count UTLI I / B IAT

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Simulation inference

IAT UTLI I / B Part A Count Part B Count Part C Count Bottleneck where 10 675 / 325 100 67 67 Conveyor 1 25 805 / 195 40 67 39 Conveyor 2 15 675 / 325 67 67 67 No bottleneck

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Original Proposal

Virtual Model

Impr.

La yout Ana lysis

Total floor space 147,500 122,500 17%

Building expansion **ft 37,500 12,500 67%

Construction cost 1,200 400 67%

Distance traveled (ft / week) 69242 49,104 29%

Transportation time (hr/week) 17.9 14.1 21%

Ca pa c it y Ana lysis No of X machines 7 6 14% Savings due to X 10,500 9,000 14% No of Y machines 4 2 50% Savings due to Y 1,460 730 50% Bottleneck (uph) 158 166 5% Tooling cost 21,960 19,730 10%

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IMTI’s R& D program

- Hybrid Environment - Interactive Environment - Immersive Environments - Smart objects - Integrated - Collaborative

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Virtual Shop Floor

VIRTUAL MANUFACTURING IMTI FLOW IMTI VIEW

Pan, ZoomFlythrough

IMTI

BROWSER CollaborateMarkup

IMTI PLAN

Tooling, Jigs, fixturesProcess Planning

Material flow Work flow IMTI CAD Smart objects Cost database IMTI OPT Optimization Scheduling IMTI SIM

Simulation & Control Analysis

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Virtual Shop Floor

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Benefits

• Reduce cycle time

• Launch new product faster

• Modify shop based on new products

• Improved communications

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Challenges

• Developing integrated robust systems

• Adopting the model to corporate culture

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WP1 WP2 WP3 WP4 WP5 Work Packages Based On GMD’ s require ments IMTI University Vendors Others

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