Virtual manufacturing - Incose

yardbellAI and Robotics

Nov 14, 2013 (3 years and 6 months ago)

59 views



















Virtual Manufacturing





Anna Chernakova












2



Biomedical

U.S. Manufacturing



Global Leadership Through



Modeling and Simulation











The long
-
term national and economic security of

the United States is increasingly dependant on

innovative and agile manufacturing capabilities.

The new focus should be on
“simulation
-
based

manufacturing”...



U.S. Council on Competitiveness, March 2009




















3





Agenda:



1.

Inspirations


2.

Rome reborn: one of the largest 3D models



3.

Intro to Virtual Manufacturing (VM)


4.

VM Case studies


5.

Future of VMS




















4

There’s not one defining moment which led me to Virtual Manufacturing….





Design/Process Errors

Design for Manufacturability



















DFM, 2010

5






/

Rome,

1000BC


550AD



















DFM, 2010

6






Italo Gismondi



















7






Plastico di Roma Antica

1933
-
1971

1:240



















8






Bernard Frischer
















1
11

9




Rome Reborn


1997
-
2007




Institute for Advanced Technology in the Humanities, UV



UCLA Cultural Virtual Reality Laboratory



Reverse Engineering Lab, Politecnico di Milano





Purpose of 3D model
:



-

present information











-

to create the cyberinfrastructure whereby the










model could be
updated, corrected, augmented










-

do experiments



















10






http://earth.google.com/rome/











11



Biomedical


Intro to VM

The next revolution in manufacturing.








Biomedical


3D
MODELING,

SIMULATION



MANUFACTURING












12

VM benefits


Reduce development and manufacturing
cost




Reduce time
-
to
-
market




Enhance communication




Enhance Yield












13

Why Virtual manufacturing?



Cost

`
Complexity

`
Win/Win



Preserves the advantages of the original system


Does not introduce any new disadvantages


Eliminates the deficiencies of the original system
















14



Biomedical


Industry Case Studies

Automotive (Ford)


Aerospace (Boeing, AAI)


Electronics (Mentor Graphics)


Microelectronics (IBM)


Data Storage (Seagate)


















15






Ford

The next revolution in global
manufacturing




Aerospace



Automotive



Biomedical



Electronics











16




Ford: Prototype builds





Advanced digital pre
-
assembly engineering checks on a new
prototype > 10,000




Reduced potential manufacturing concerns by > 80%




Reduced design and production tooling issues by 50%




Improved quality by 11% (industry average 2%)




40% of Ford’s testing is done virtually, 5%
-
10%








without

a physical

prototype.












17




Ford: ROI

Products





A 305
-
horsepower Mustang with 31 mpg on the
highway.




An economy car with a six
-
speed automatic
transmission with all the fuel economy of a manual.



A whole line of cars that literally
park themselves
.













18



Ford: Advanced 3D modeling

The next revolution in global
manufacturing




Aerospace



Automotive



Biomedical



Electronics











19




Ford: Virtual Environment




Programmable Vehicle Model











20




Ford: Improving quality through VM

















21





Ford: Virtual Checklist

Finding problems before the physical
build














22




Boeing:









Simulating the entire









assembly process












23




Boeing: ROI


Boeing is saving more than 2,000,000$ annually due to VM.


VM center (2008) built in Ohio to develop prototypes:


-

compressed development cycle


-

all what
-
if scenarios in the 3
-
D environment


-

enhanced collaboration and teamwork











24




Boeing: ROI

.

“The VMC will make Boeing more competitive by
expanding its capabilities to inject technical and
engineering data in to the manufacturing process
in a very cutting edge way …with prototypes that
have not yet been produced.”







25

and VM


Solutions





Accelerate

the

development

cycle

by

using

advanced

fluid

dynamics

(CFD)

software






Develop

staff

with

a

focus

on

simulation





Create

a

virtual

wind

tunnel

to

reduce

time/cost




Simulate

different

configurations,

modifications

and

payloads
.






Analyze

impact

of

design

changes

on

prototype’s

propeller,

fuselage,

etc
.





AAI Corporation

Challenge


Improve AAI’s competitive position in the unmanned aerial vehicle (UAV)
marketplace.







26

and VM



Return on Investment




Increases aircraft endurance due to decreased fuel consumption, resulting in
reduced costs per flight hour


• Compresses design cycle, reducing physical prototyping costs and development
costs


• Company’s move into new era of advanced UAV design ramped up their
competitive position


• AAI is better able to meet customer requirements with a better product in less
time

AAI Corporation











27



Biomedical

Electronics: PCB








Biomedical











28



Biomedical

PCB and Mentor Graphics








Biomedical











29



Biomedical

Mentor's Valor MSS Solutions








Biomedical


-

Design, planning, monitoring, control, scheduling, traceability, test and
rework processes of PCB assembly operations.


-

Eliminating waste, including materials and energy, leading to reduced
environment and financial costs (founded on the principles of “Lean
Thinking”)


-

Unique global visibility of all operations, tasks, resources, activities
and traceability based on a 3D live manufacturing view and business
intelligence reporting .



















30




Microelectronics:
Complexity and Cost



3D Processor DRAM Integrated Systems



Single wafer cost:

-

$100,000 for specialized MEMS devices









-

$1,000,000 for nm design on 300mm wafer



















31




IBM 22nm and beyond technology




-

emulate advanced integrated processes


-

modeling of a complete process sequence


-

creates realistic 3D models that can be shared



“Our
visibility

into the full technology implication of process
selections and changes has been improved. SEMulator3D
has helped IBM
predict problems
that otherwise would only
have been found by subsequent testing and physical failure
analysis."







David Fried, 22nm chief technologist, IBM.











32







How Does It Work?

Viewer

Modeler


Process

File

2
.) CAD Layout


1.) Parameterized
Process Description

3.) Modeler combines
Process and CAD inputs

to emulate the device

4.) Use the Viewer
module to view the
emulated device in 3
-
D







34



MEMS
(micro
-
electro
-
mechanical systems)
VM


















35



Seagate:


Building Virtual Product&Process





















3D Modeling











DFM










DRC











DFSS








System Automation












36



Seagate:


















II. Magnetic head


-

>1000 steps

-

~ semicon process

-

complex

I. Slider

-

few steps

-

highly critical





VM


Slider




Design

-
Direct savings of $500K annually in direct labor cost .


-

Indirect savings due to drastic reduction of design errors.


ROI:






Page
38

VM flow

Model

Optimization










Model

Verification


3
D model

(application) specific


Process
-
aware

Design






Page
39

VM Example

Process

Variations

Simulation




3D Model





Design for

Manufacturing


Design Rule Checks









Select Design Type

(Full factorial, RSM, etc)


Define Actual Input Parameters

DOE1

DOE 2
….

DOE n

Model
1
Model
2
…..

Model n

40

DOE generator





Critical Target(s)

Input parameters


DOE Generator


Virtual Model


Virtual Model
Library

Data Analysis

Virtual metrology/DRC

Real process/device
metrology

CT
Opt
= TF (IP
Opt
)

Real process/device

Virtual Model Calibration/Validation

Target Verification

Input Distribution


41

Virtual Optimization











42



Biomedical


VMS









Biomedical


3D
MODELING,

SIMULATION



MANUFACTURING


Virtual
experiments
generator/Op
timizer


DFM


DRC

DFT











43



Biomedical

U.S. Manufacturing



Global Leadership Through



Modeling and Simulation











The long
-
term national and economic security of

the United States is increasingly dependant on

innovative and agile manufacturing capabilities.

The new focus should be on “simulation
-
based

manufacturing”...



U.S. Council on Competitiveness, March 2009








44


US Council on Competitiveness
and VM



“Grand Challenge Case Study: Vehicle Design.”

Full Vehicle Design Optimization for Global Market Dominance

Requirement Categories

Computational Method

Body Styling

3D Full Body Computer Aided Design

Crash Worthiness

3D Dynamic Structural Deformation Analysis

Vehicle Structural Integrity

Finite Element Structural Analysis

Fuel Efficiency

Computational Fluid Dynamics

Passenger Comfort (Noise and Vibration)

Acoustics and Finite Element Analysis







45


Council on Competitiveness Case Studies
and VM



“Grand Challenge Case Study: Vehicle Design.”

Multiple, independent simulations


Single, integrated model








46


Council on Competitiveness Case Studies
and VM



“Challenge Case Study: Auto Crash Safety”



-


Optimize the safety of a vehicle by measuring the effects of a crash on
all of the physical attributes of the human body


-


Mathematical model of the full human body, a “grand challenge” in
itself to develop


-


Integrate this highly complex model into already complex crash
simulations







47


Council on Competitiveness Case Studies
and VM



“Challenge Case Study: Auto Crash Safety”





















Virtual Manufacturing



Prototype the future: one in
which virtuality will change
and enhance the way we
work and live.




















Backup slides








“No Defect “ Design

Misalignment


DOE Generator

81 virtual models




Automatic Error Detection

P

R

O

C

E

S

S

No defect

Change Design

Visual inspection & Analysis

Defect

DFM, 2010

50











DFM, 2010

51







52


Council on Competitiveness Case Studies
and VM



“Grand Challenge Case Study: Vehicle Design.”

Full Vehicle Design Optimization for Global Market Dominance

Auto Crash Safety Study


Crude Oil Catalysts Study


Oil and Gas Recovery Study


Textile Manufacturing Study