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Copyright ESI Group, 2014. All rights reserved.,1,Immersive Process Engineering in Automotive Final Assembly,Dr. Michael KerauschProduct Marketing Manager IC.IDOSeptember 2014,Current Customer Workflow,Situation & Limitations on customer side Static and theoretical analysis/discussions of the assembly sequencesNo adhoc changes order of assembly sequence“ during the meetingMany problems can be validated with the first prototype onlyNo interactive usage of tools and parts ( rigid, flexible ) in real-timeComplicated software usage by specialistsMany manual steps are required to perform a specific analysisNon interactive and realistic 1:1 viewing,3,Absence of Value,Interactive Workflow,Virtual Build,Planning,Manufacturing,Planning,Manufacturing,Definition,Development,Maintenance,IC.IDO in Product Development Process,5,Virtual Engineering,Virtual Build,Virtual Service,Start,Concept,Freeze,SOP,EOL,Study,Concept,After Sales,Design,Use Case Virtual Build“ and Digital Factory,- 33,- 30,- 19,- 8,0,SOP,Purchase Approval,ConceptDecision,Virtual Product-Process Validation,Product data,Process data,Resource data,Environment data,CAE data,Industrial Approach,Virtual Product Process ValidationVisualize product dataAnalyse of assembling process dataassembling processAnalyse of assembling environmentshandling devicestoolsAnalyse of ergonomic manufacturing/assembling issuesWorker movements,Virtual Product Process ValidationVisualize product dataAnalyse of assembling process dataassembling processAnalyse of assembling environmentshandling devicestoolsAnalyse of ergonomic manufacturing/assembling issuesWorker movements,Seq. 1,ZSB Fueltube,Seq. 2,Engine-Cable,Seq. 3,Holder Engine-Control,Seq. 4,Damping Engineroom,Seq. n+1,Example Wiper Mechanism,Customer Stories AUDI AG,Source: Audi AG,Customer ChallengeEasy verifying of assembly sequence processes to initiate considerable savings in production and manufacturing development. It helps also to create production processes planning without using physical hardware prototypes.,“Already well before a physical prototype is available we are able to validate a lot of assembly sequences early in the project without any expensive materials and tools. And if necessary we can adopt these sequences. Thus, we are saving money, increasing quality of production process and get early readiness for start of production.“Katharina Kunz, CAVE Audi Pre-Series-Center,Example Door Glass,11,10min,2min,1min,2min,50x3min,Manual assembly in 2h 45min,15min,2min,2min,2min,5min,Assisted assembly in 30min,Benchmark Assembling Validation,“classical” CAD / DMU,Disassembly Scenario Example,Planning,Manufacturing,Planning,Manufacturing,13,Definition,Development,Maintenance,Start,Concept,Freeze,SOP,EOL,Study,Concept,After Sales,Design,IC.IDO Footprint in Automotive,Massive cost savings through fewer change orders in the processVirtual dynamic verification of product and sequence processes makes the product development faster Integrated and efficient product development without any physical hardware dependencies and reduced production downtimes Fundamentally better quality during ramp up phase by avoidance of mistakes and identification of problematic issues,Benefits,Agenda,16,Customer ChallengeUse CaseCustomer StoriesAdvantages & Benefits,Targeted validation issues of production simulationGeneral manufacturabilitySequence of manual assemblingFeasibility of manual assembling (resp. humans, tools, etc.)Composition of work-cells (resources, layout, paths, etc.)Applicability of production planning on variantsCompliance with formalitiesRespecting real-time simulation ofPhysical behavior (mass, collision, gliding, gravity)Human model and interaction techniquesElastic and pre-formed partsCAE-results,Positioning of IC.IDO in Manufacturing Validation,17,Concept for validating production simulationConsolidating data out of different sources in one VR-System supporting direct interfacesVR-solution with leading edge simulation technology and approved user-interfacesFocused on natural interaction technology to be used by non-IT-expertsProviding real-time simulati

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