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Smart Assembly Systems

Smart Assembly Systems. GM Perspective Roland Menassa Laboratory Group Manager Agile Equipment and Processes Manufacturing Systems Research Laboratory General Motors R&D. Industry Trends are Driving Increasing Need for Innovation.

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Smart Assembly Systems

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  1. Smart Assembly Systems GM Perspective Roland Menassa Laboratory Group Manager Agile Equipment and Processes Manufacturing Systems Research Laboratory General Motors R&D

  2. Industry Trends are Driving Increasing Need for Innovation • Consumer driven industry with fierce competition – High option content • Product life about 5 to 6 years with major mid-cycle enhancement every 3 years • Production volume varies between 20k to 300k per plant per year (10 to 65 JPH)

  3. Automotive Industry ChallengesAnd Key Technologies

  4. Creating the Next Paradigm in Automotive Manufacturing SmartManufacturing (World Wide Web Analogy) The paradigm beyond ‘lean’ will be driven by the availability and exploitation of real-time information across the manufacturing enterprise (Big M) to optimize the value chain from suppliers through manufacturing plants and into the distribution channel Taiichi Ohno: Lean Mfg. (Grocery Business) Henry Ford Assembly Line(Meat Packaging) Henry Leland Interchangeable Parts(Gun Industry) Craft Manufacturing

  5. Technological Discontinuities in Manufacturing Arena • Pervasive sensing • Pervasive communications • Pervasive device intelligence • Pervasive servo actuation • Pervasive simulation/visualization Real Time Mfg Agile Virtual

  6. “BIG M” vs. “small m” Manufacturing MARKETING SUPPLIERS “M”-mfg v MATERIALS “m”-mfg DESIGN OUTSIDEPLANT INSIDEPLANT ELECTRONICS Focus of this talk: “Smart Assembly” as it relates to putting stuff together

  7. Typical Vehicle Assembly Plant Body Shop Paint Shop General Assembly • 2.5 – 3.5 million sq feet • 400-600 robots • 400-600 PLC’s • 20-25 miles of conveyors • 800-1200 vehicles in the system • 1000-1200 operators/shift • 60 vehicles/hour output

  8. Business DriversWhat problems do we want to solve? • Time to Market • Reduce time to launch and accelerate • Cost • Reduce hours Per Vehicle (Direct cost) • Improve maintenance efficiency (Indirect cost) • Reduce engineering cost (Structural cost) • Throughput • Minimize/eliminate downtime • Optimize resource utilization/balancing • Quality • First time quality • Responsiveness/Flexibility • Build any product in any plant

  9. Some trends related to Smart Assembly

  10. Lots of energy around interoperability and standards for plant floor communications

  11. Wireless Technology We’re working on wireless…

  12. People are talking about integration of “Virtual” and “Physical”

  13. Cooperative Robots Cooperative Robots is a “hot topic”

  14. Asimo (Honda) Partner (Toyota) Humanoid Robots Denso “Safe” Mobile Robot • The Japanese Automotive OEMs are targeting Humanoid robots at 3 areas; • Marketing – Technology as Public Relations • Products – Personal Robots providing Service, Mobility, and Entertainment • Manufacturing – Replacement of Manned Operations The Technologies that have been developed for Humanoid Robots are being deployed in Manufacturing These things are coming…. Yaskawa “Dual” Armed Robots Yaskawa “Snake” Robot

  15. Virtual Training Augmented Reality and Wearable Computing is happening.

  16. “Flight Simulator” technologies are being applied to industrial applications.

  17. Programmable fixtures for flexibility and dimensional control are in use… Flexible End-Effector Servo Driven Locating and Clamping Flexible Stationary Fixture C-Flex

  18. Key Characteristics/Attributes • Time to market • “Manufacturing Validation” process is eliminated. Becomes continuous improvement of a process that is already “in control”. • “Virtual Factory” analogous to “Flight Simulator” for aircraft • “Virtual” and “Real-time” fully synchronized. • Upload real to virtual. Virtual systems “understand” the plant floor. • 100% of plant “in math” • Cost • “Intelligent” cooperative robots in General Assembly • Near-zero reactive maintenance • Centralized remote and highly automated diagnostics/prognostics. • Minimized disruption to plant floor for new products. • Smart design for reduced HPV. • No redundant data, and constraints automatically propagated between systems. All “systems” converged into one logical “do work” portal. “Engineering factory” is “error-proofed”.

  19. Key Characteristics/Attributes • Throughput • Highly automated “error-recovery”. (Eg: re-allocation of work to robots). • Effective plant floor decision support tools. Interoperability from “shop floor” to “top floor”. • Re-configurable factory. • Agent-based, distributed controls and networks • Quality • Adaptive dimensional control. • Responsiveness/Flexibility • “Re-programmable factory.” • Download virtual to real. Real time systems “understand” virtual. • From hardware to firmware changes for new products. • Real time “remote control” of factory • Pervasive sensing and wireless • Plug and Play plant floor devices. • Re-useable plant

  20. Q & A…

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