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Virtual Manufacturing Anna Chernakova

Virtual Manufacturing Anna Chernakova . 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”...

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Virtual Manufacturing Anna Chernakova

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  1. Virtual Manufacturing Anna Chernakova

  2. 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 U.S. Manufacturing – Global Leadership Through Modeling and Simulation Biomedical • 2

  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 3

  4. There’s not one defining moment which led me to Virtual Manufacturing…. Photorealistic 3D Simulations 3D Transistor Model Design for Manufacturability Design/Process Errors Design for Six Sigma 3D Model of Magnetic Head Process 4

  5. Rome, 1000BC – 550AD / DFM, 2010 5

  6. Italo Gismondi DFM, 2010 6

  7. Plastico di Roma Antica 1933-1971 1:240 7

  8. Bernard Frischer 8

  9. Rome Reborn 1997-2007 111 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 9

  10. http://earth.google.com/rome/ 10

  11. Intro to VM MANUFACTURING 3D MODELING, SIMULATION The next revolution in manufacturing. Biomedical Biomedical • 11

  12. VM benefits • Reduce development and manufacturing cost • Reduce time-to-market • Enhance communication • Enhance Yield • 12

  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 • 13

  14. Industry Case Studies Automotive (Ford) Aerospace (Boeing, AAI) Electronics (Mentor Graphics) Microelectronics (IBM) Data Storage (Seagate) Biomedical • 14

  15. Ford The next revolution in global manufacturing Aerospace Automotive Biomedical Electronics • 15

  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. • 16

  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. • 17

  18. Ford: Advanced 3D modeling The next revolution in global manufacturing Aerospace Automotive Biomedical Electronics • 18

  19. Ford: Virtual Environment Programmable Vehicle Model • 19

  20. Ford: Improving quality through VM • 20

  21. Ford: Virtual Checklist Finding problems before the physical build • 21

  22. Boeing: Simulating the entire assembly process • 22

  23. 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 Boeing: ROI • 23

  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.” • 24

  25. and VM AAI Corporation Challenge Improve AAI’s competitive position in the unmanned aerial vehicle (UAV) marketplace. • 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. 25

  26. and VM AAI Corporation 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 26

  27. Electronics: PCB Biomedical Biomedical • 27

  28. PCB and Mentor Graphics Biomedical Biomedical • 28

  29. 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 . Mentor's Valor MSS Solutions Biomedical Biomedical • 29

  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 30

  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. 31

  32. 32

  33. How Does It Work? ProcessFile 3.) Modeler combines Process and CAD inputs to emulate the device 1.) Parameterized Process Description 4.) Use the Viewer module to view the emulated device in 3-D Viewer Modeler 2.) CAD Layout ‏

  34. MEMS (micro-electro-mechanical systems)VM 34

  35. Seagate: Building Virtual Product&Process 3D Modeling • DFM DRC DFSS • System Automation • 35

  36. Seagate: I. Slider • II. Magnetic head • >1000 steps • ~ semicon process • complex • few steps • highly critical • 36

  37. VM – Slider Design ROI: • Direct savings of $500K annually in direct labor cost . • - Indirect savings due to drastic reduction of design errors.

  38. 3D model (application) specific Process-aware Design Model Optimization Model Verification VM flow • Page 38

  39. Process Variations Simulation VM Example 3D Model Design for Manufacturing Design Rule Checks • Page 39

  40. DOE generator Select Design Type (Full factorial, RSM, etc)‏ Define Actual Input Parameters DOE n DOE 2 …. DOE1 Model n Model 1 Model 2 ….. 40

  41. Virtual Optimization Target Verification Critical Target(s) Input Distribution Input parameters DOE Generator Virtual Model Library Virtual Model Calibration/Validation Virtual Model Real process/device metrology Virtual metrology/DRC Real process/device Data Analysis CTOpt= TF (IPOpt) • 41

  42. Virtual experiments generator/Optimizer MANUFACTURING VMS 3D MODELING, SIMULATION DFM DRC DFT Biomedical Biomedical • 42

  43. 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 U.S. Manufacturing – Global Leadership Through Modeling and Simulation Biomedical • 43

  44. US Council on Competitiveness and VM “Grand Challenge Case Study: Vehicle Design.” Full Vehicle Design Optimization for Global Market Dominance 44

  45. Council on Competitiveness Case Studies and VM “Grand Challenge Case Study: Vehicle Design.” Multiple, independent simulations Single, integrated model 45

  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 46

  47. Council on Competitiveness Case Studies and VM “Challenge Case Study: Auto Crash Safety” 47

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

  49. Backup slides

  50. “No Defect “ Design Misalignment DOE Generator Change Design 81 virtual models Automatic Error Detection P R O C E S S No defect Defect Visual inspection & Analysis DFM, 2010 50

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