Lecture about Virtual production
Here's a summary of the lecture objective and important concepts from the lecture "Virtual Production Planning".
Lecture Objectives
1. Learn how virtual production planning improves efficiency and reduces production time in manufacturing.
2. Understand the concept of a digital twin and how it helps in modern production.
3. Explore how virtual production supports Industry 4.0 by connecting digital tools with real-world manufacturing.
4. Discover the benefits of virtual commissioning, such as saving time and improving software quality.
What does this word "virtual commissioning" mean?
5. Recognize the role of system like CAD, PLM, ERP, and MES in virtual production.
Key Concepts
1. Why Virtual Production matters
- Virtual production helps manufacturers work faster and save money by simulating production processes before they start.
- Instead of relying on physical prototypes, validation happens in a virtual environment, making the process more efficient and flexible.
2. Industry 4.0 and the Digital Twin
Industry 4.0 is defined as the latest wave of digital manufacturing that connects virtual models with real-time production data.
Digital twin is a virtual replica of a factory or production process that allows manufacturers to test and optimize systems without disrupting real operations.
Why use digital twin:
- Speed up production launches.
- Analyze "what-if" scenarios to improve designs and operations.
- Track and optimize supply chain processes.
3. Virtual Commissioning
What it is: Virtual commissioning is testing systems logic in a virtual space before using them in the real factory.
Benefits of virtual commissioning:
- Less on-site testing.
- Lower costs and faster project timelines.
- Improved software quality and productivity.
- Provides virtual training opportunities.
4. Systems Supporting Virtual Production (most important part are highlighted)
CAD (computer-aided design): Tools for designing digital models of products and equipment.
PLM (product lifecycle management): Manages the full lifecycle of a product, integrating product data, manufacturing processes, and work people.
ERP (enterprise resource planning): Organizes business processes like inventory, scheduling, and finances.
MES (manufacturing execution systems): Tracks production in real time to optimize operations.
APS (Advanced planning and scheduling): Helps balance resources use and meet production goals. Helps planning production schedule and workers time schedule.
5. Virtual Production workflows
Steps in the processes
1. Product designs.
2. Simulating and validating resources and processes.
3. Detailed production planning and programming.
4. Shop-floor integration of resources like robots and tools.
By running planning and simulation together, manufacturers minimize errors and improve efficiency.
6. Manufacturing Bills of Materials
EBOM (Engineering Bill of Materials): Details the product design.
MBOM (Manufacturing Bill of Materials): Focuses on the parts and materials needed for production.
BOP (Bill of Process): Explains the production steps and methods.
BOR/BOF (Bill of Resources/Factory): Lists tools and resources needed for manufacturing.
7. Benefits of virtual production
- Reduces production cost and speeds up timelines, so its both cost and time savings.
- Standardized production processes ensures consistency in product quality, improved quality than before.
- Better collaboration: Digital models make it easier for teams to communicate.
- Knowledge retention: Virtual models store valuable information for future use.
