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In the ever-evolving world of manufacturing, especially within the automotive sector, the challenge of integrating new processes or equipment into an active production environment is immense. Imagine you're a manufacturing engineer tasked with revamping a plant to produce a new electric vehicle variant. This scenario involves a complex process with numerous variables, and the success of such a project hinges on several critical factors.
Understanding the product and process
Successful project planning requires close collaboration with the design department to thoroughly understand a new product. Key questions naturally arise, such as “how many variants are expected?” and “what process validations and quality checks are necessary?” And crucially, “is the product design genuinely frozen?” In reality, a true design freeze is nearly impossible in such an environment, which adds another layer of complexity to the task.
Equally important is creating a strategy to ensure the quality and revenue of the existing production lines. Minimizing both planned downtime (for installation and commissioning) and unplanned downtime (due to unforeseen errors) is non-negotiable. These considerations are critical for any experienced manufacturing engineer.
The factory digital twin - a game changer
Amongst these challenges, one of the most transformative tools emerging is the digital twin. This innovative technology offers a dynamic solution by providing up-to-date, comprehensive shop floor data. This capability becomes even more crucial when managing multiple projects simultaneously or overseeing a team of engineers with many ongoing initiatives.
Digital twins are poised to redefine how engineers approach manufacturing. By creating a virtual replica of the factory environment, engineers can evaluate various production scenarios and options with a level of precision that was previously unattainable.
The rapid pace of change
The manufacturing industry is experiencing unprecedented change. New electric vehicle manufacturers are competing fiercely, while traditional automotive companies and their supply networks race to transition from internal combustion engines to electric production. In this fast-paced environment, having an accurate, comprehensive representation of global production networks is essential for making informed strategic decisions and avoiding costly errors.
Global travel has traditionally been used to mitigate risks and inefficiencies, but it comes with significant costs and environmental impacts. The drive for sustainability has also intensified, with manufacturers focusing on reducing energy consumption and CO2 emissions. Smart manufacturing, digitalization, and Industry 4.0 initiatives are all geared towards achieving lean, cost-efficient operations from both production and administrative perspectives.
What is a digital twin?
Digital twins come in various forms, but for our purposes, we’ll focus on the factory digital twin. This model involves scaled, geolocated visual and spatial data, allowing for optimized layouts, collision detection, and streamlined production systems. Unlike product digital twins, which involve design data directly controlled by the manufacturer, factory digital twins often rely on external data sources and may include low-value assets like tools and parts racks.
The collection of this data, traditionally a cumbersome process involving static scans and significant computational demands, has been revolutionized by advancements in laser scanning and cloud computing. Technologies such as LiDAR-based, wearable laser scanning devices like the NavVis VLX 3 have drastically improved data collection speed and accessibility.
The impact of modern scanning technology
NavVis, a pioneer in this field, leverages cutting-edge wearable laser scanning technology to capture high-resolution, geolocated data efficiently. This data is then processed and made accessible via the NavVis IVION software platform, providing a virtual navigation experience similar to Google StreetView.
The benefits of digital twin technology are significant. For instance, BMW, a prominent user of NavVis digital twin solutions, has integrated over 9 million square meters of indoor space and 15 million square meters of indoor space into NavVis IVION. This extensive use has led to significant returns on investment, with over 30,000 employees utilizing the data.
Real-world benefits and use cases
The real-world applications of digital twin technology are vast and impactful. For global enterprises, digital twins facilitate instantaneous site evaluations, strategic decision-making, and significant reductions in travel costs. For manufacturing and industrial engineering, they enable precise concept evaluations, equipment specifications, and significant reductions in downtime.
Additionally, digital twins support shop floor management, maintenance processes, and 5S audits. By leveraging advanced visual positioning and mobile apps, manufacturers can streamline operations and document critical findings effectively.
In summary
The factory digital twin is not just a technological advancement but a vital tool for modern manufacturing. It bridges the gap between complex production environments and strategic decision-making, offering a clear path to enhanced efficiency and substantial cost savings. As the industry continues to evolve, embracing digital twin technology will be crucial for staying competitive and achieving sustainable success.
With over 20 years of experience in the automotive industry, the western North Carolina native Nate McCall supports US manufacturing competitiveness as a Senior Solution Manager at the deep tech / reality capture company, NavVis. Nate holds a degree in mechanical engineering from Clemson University, and began his career at Robert Bosch Corporation in Charleston, South Carolina and further expanded his expertise during his tenure as an expatriate in Bamberg, Germany. Later, at BMW, Nate suppored the launch of several vehicles at the Spartanburg plant. He contributed in various capacities, both from the Upstate of South Carolina and as an expatriate in Munich.