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Realize Innovationcards PLM Solutions
Designing workplaces of the future
Björn Hoeven | Dr. Gert Nomden
21 March 2019 Restricted © cards PLM Solutions 2
Virtual Plants involve a comprehensive set of software tools to:
• Define, simulate and optimize manufacturing, logistics and maintenance operations through virtual models.
• Capture and exchange information about those operations, both simulated and real-life, thereby closing the feedback-loop between planning and execution.
Virtual Plant
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Principles of Virtual Plants
Existing or new plant Virtual plant model
Specifications, simulations,
analyses, reports,
communications
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Highlights:
• Industrial PC
• Designed for rough environments. High-quality industrial design
• Vibration and shock resistant. Wide temperature range
• Electromagnetic compatibility. Still small in space (1 Liter)
Assembly example: Nanobox
Design tools
Design NastranAutomotive MCDLineDesigner
• Identify bottlenecks
• Optimize throughput
• Buffer dimensioning
• Optimize lot-sizes/
production mix
• Optimize number of
part-carriers
• Optimize robot position
based on reachability
• Robot OLP
• Exact cycle times
• Human Ergonomics
Plant SimulationProcess Simulate -
Robotics | Human
Virtual
CommissioningVirtual
Reality
AdditiveCAM
Integrating the digital and real worldProduct Information is enriched throughout the life cycle
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Digital World
Requirements
Product Structures
Virtual Product Models
Digitalization Work instructions
Quality information
Production-Simulation
Planning Configuration
Validation
Virtual Commissioning
Digital Equipment Ramp up / Operation
Monitoring
Optimization - CI
Integrated Plant Documentation
Maintenance
Condition monitoring
Service
Real World
ServiceProductionProduction
planning
Product-
design
Production-
Engineering
The digital model is always up to date and will be expanded
throughout the life cycle
Integrating the digital and real worldProduct Information is enriched throughout the life cycle
21 March 2019 Restricted © cards PLM Solutions 7
Digital World
Requirements
Product Structures
Virtual Product Models
Digitalization Work instructions
Quality information
Production-Simulation
Planning
Real World
ServiceProductionProduction
planning
Product-
design
Production-
Engineering
The digital model is always up to date and will be expanded
throughout the life cycle
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Highlight:
• Setting-up the production layout
• Smart equipment
Layout design
Integrating the digital and real worldProduct Information is enriched throughout the life cycle
21 March 2019 Restricted © cards PLM Solutions 9
Digital World
Requirements
Product Structures
Virtual Product Models
Digitalization Work instructions
Quality information
Production-Simulation
Planning Configuration
Validation
Virtual Commissioning
Digital Equipment
Real World
ServiceProductionProduction
planning
Product-
design
Production-
Engineering
The digital model is always up to date and will be expanded
throughout the life cycle
21 March 2019 Restricted © cards PLM Solutions 10
Highlights:
• Task timing
• Workcell verification
• Ergonomic validation
Human simulation
Ergonomic standards
Supported ergonomic tools include:
• OWAS - Ovako Working posture Analyzing System
• NIOSH - National Institute for Occupational Safety and Health
• SSP – University of Michigan 3D Static Strength Prediction Program
• FRA – Fatigue and Recovery Analysis tool
• DMH - Distributed Moment Histogram/Lower Back Analysis
• RULA - Rapid Upper Limb Assessment
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Highlights:
• Off-line programming
• Task timing
• Collision detection
• Cell optimization
Robot simulation
Integrating the digital and real worldProduct Information is enriched throughout the life cycle
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Digital World
Requirements
Product Structures
Virtual Product Models
Digitalization Work instructions
Quality information
Production-Simulation
Planning Configuration
Validation
Virtual Commissioning
Digital Equipment Ramp up / Operation
Monitoring
Optimization - CI
Integrated Plant
Real World
ServiceProductionProduction
planning
Product-
design
Production-
Engineering
The digital model is always up to date and will be expanded
throughout the life cycle
21 March 2019 Restricted © cards PLM Solutions 14
Highlights:
• Nanobox factory model
• Real-time interactive optimization
Plant optimization
Integrating the digital and real worldProduct Information is enriched throughout the life cycle
21 March 2019 Restricted © cards PLM Solutions 15
Digital World
Requirements
Product Structures
Virtual Product Models
Digitalization Work instructions
Quality information
Production-Simulation
Planning Configuration
Validation
Virtual Commissioning
Digital Equipment Ramp up / Operation
Monitoring
Optimization - CI
Integrated Plant Documentation
Maintenance
Condition monitoring
Service
Real World
ServiceProductionProduction
planning
Product-
design
Production-
Engineering
The digital model is always up to date and will be expanded
throughout the life cycle
Motion Capture
Allow Engineers and subjects to explore virtual designs by becoming immersed
• Use subject motions to move the virtual figure
• Record motions of complex tasks
• Experience designs first hand
• Gather objective and subjective responses
Entry-level motion capture
MS Kinect
• No special requirements
• Use with Kinect for Windows SDK
• Voice and gesture command
Capabilities:
• Explore the scene
• Capture critical postures
Use direct feedback
Re-use postures in simulations
High-end motion capture
• Broad range of tracking hardware supported
• Optical, electro-magnetic, inertial, data-gloves
• Track whole body, hand and head motions
• Track multiple actors and objects simultaneously
• Immersion technologies (VR)
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Highlights:
• Live measurement of ergonomics
• Real-time workplace improvement
Human simulation
Using PLM software to realize multi-disciplinary co-operation
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Engaged Users
Right information.
Right time. Right context.
Intelligent Models
Knowing what they are
and how they’re made.
Adaptive System
Easy deployment today.
Flexibility for tomorrow.
Realized Products
Virtual product.
Real production.
Smart Manufacturing…
and the REAL value is?
Know:
▪ That your design can be made
▪ That the plan is up-to-date and synchronized
▪ That the production system is up-to-date
▪ That the strategy and details will work
▪ How to improve effectiveness and maximize
performance
▪ That production is performing as you planned it
Speed Flexibility Quality Efficiency
21 March 2019 Restricted © cards PLM Solutions 22
Dr. Gert NomdenSenior Consultant
cards PLM Solutions BV
De Maas 22A | NL-5684 PL Best
M: +31 6 2282 7248
gert@cards-group.com | www.cardsplmsolutions.com
Contact
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