B K C L OZE ULKA OE M > K , VIRTUAL CONCEPT REAL PROFIT S , [ed.] AWSKI with Digital Manufacturing and Simulation IR E , S , , , O VIRTUAL CONCEPT In our highly competitive industrialized world of lean production TT O and fast innovation, it comes as no surprise that customers demand CASA Yves Coze instantaneous delivery of individualized products at the best price- , , > performance ratio. For manufacturing companies, vast product REAL PROFIT ranges of high quality and complexity mean that flexible develop- with Digital Manufacturing and Simulation VIRTUAL CONCEPT ment and ramp-up across supply chain networks is crucial to survive with Digital Manufacturing and Simulation and thrive. Global competition, economic pressure, environmental and energy issues demand state-of-the-art capabilities and, above all, timely action. Such formidable challenges can only be met by Nicolas Kawski tightly interwoven lifecycle-oriented engineering and manufactur- ing technologies and processes. To date more than ever, the ongoing development and integration of digital manufacturing and simu- lation is critical to eliminate the waste of time and money in the physical world, and to ensure product success as much and as early as possible. Torsten Kulka Digital manufacturing and simulation clearly constitute contempo- rary extensions of the train of thought and practice that Frederick Winslow Taylor started a century ago. The evolution from “Taylor- > made” to “tailor-made” is in perfect concert with the ongoing REAL PROFIT customization that customers have learned not only to demand but to even co-create. Apart from lowering cost and improving time- to-market, digital manufacturing and simulation are targeted at Pascal Sire intensifying the intimacy, efficiency and effectiveness of co-creation feedback loops, fostering the collaboration of manufacturers, cus- tomer communities, independent R&D institutes and individuals. This emerging democratization of design, engineering, production, maintenance, repair, overhaul and recycling marks the impending impact of digital manufacturing and simulation. Philippe Sottocasa In five chapters this book discusses the various topics and issues that are central to the implementation and development of digital manufacturing and simulation. The first “Welcome” chapter presents key concepts, needs and issues. These are further explored in four other chapters: “A Crash Course,” “Challenges,” “Benefits” and “The Future.” Each chapter starts off with an introductory snapshot and YVES COZE concludes with a Bookmark section that relates the chapter to the NICOLAS KAWSKI other parts and the message of the book. Jaap Bloem TORSTEN KULKA Readers who would benefit from this book belong to various cat- PASCAL S IRE See “About the Authors” egories, ranging from decision makers and business developers to PHILIPPE S OTTOCASA on page 160-161. engineers, technical managers and researchers. JAAP BLOEM [ed.] ISBN 978-90-75414-25-7 I 9 789075 4 14257 Virtual Concept > Real Profit Virtual Concept > Real Profit with Digital Manufacturing and Simulation Yves Coze Nicolas Kawski Torsten Kulka Pascal Sire Philippe Sottocasa Jaap Bloem [ed.] © 2009 Dassault Systèmes and Sogeti | All Rights Reserved. Production LINE UP Book & Media, The Netherlands Editing Susan MacFarlane Editorial supervision Minke Sikkema Cover illustration Jennifer Hoarau Book design Jan Faber Printing Bariet, The Netherlands ISBN 978 90 75414 25 7 No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the publisher’s prior consent. Contents Foreword by Philippe Charlès, CEO DELMIA– Dassault Systemes Group 7 Foreword by Luc François Salvador, Chairman and CEO of Sogeti 9 About this book 11 Acknowledgement 11 1 Welcome to the Reality of Digital Manufacturing and Simulation 12 Introduction From Taylor-made to Tailor-made 14 1.1 Why Digital Manufacturing and What about Simulation 15 interview Michel Vrinat, independent consultant and Product Lifecycle research director 16 1.2 Proven Benefits of Simulation and Digital Manufacturing 21 interview Fernando Mas, CAD/CAM & Digital Mock Up Manager at EADS/ CASA 26 Bookmark Chapter 1 29 2 A Crash Course in Digital Manufacturing and Simulation 30 Introduction ManuFuture 2020 32 2.1 Simulation Through the Ages 34 2.2 Computer Simulation in Everyday Life 39 2.3 The History of Computer Simulation 43 2.4 Types of Computer Simulation 50 2.5 Definition and Development of Digital Manufacturing 53 2.6 Digital Manufacturing Projects 61 interview Frédéric Bertaud, responsible for the Airbus A350 DM Project 63 2.7 Beneficial Use of Simulation in Manufacturing 66 Bookmark Chapter 2 70 3 Challenges for Digital Manufacturing and Simulation 72 Introduction Identifying the Traps 74 3.1 Simulation in Manufacturing Systems 77 3.2 Six Grand Challenges for 2020 82 3.3 Changing Undesirable Social Behavior 86 3.4 Confronting Today’s Limits 91 5 interview Fulvio Rusino, Head Advanced Engineering at Comau 96 3.5 Automotive 2020 98 3.6 The Digital Factory Challenge 103 Bookmark Chapter 3 106 4 Benefits in Real-World Examples Introduction Current and Future Benefits 110 4.1 “Manufacturing Ready” for Maximum Profitability 112 interview Philippe Hamon, R&D Manager at LEONI Wiring Systems 113 4.2 Benefits in Perspective for Automotive 115 4.3 Benefits in Perspective for Aerospace 122 4.4 Benefits in Perspective for Shipbuilding 127 4.5 Benefits in Perspective for Consumer Goods 129 4.6 Benefits in Perspective for Energy 130 4.7 Digital Manufacturing as a Communications Platform 131 Bookmark Chapter 4 135 5 The Future is Open and Personal Introduction Towards Crowdengineering 138 5.1 From Mass Production to Mass Customization 140 5.2 Customization and Virtual Reality in 2015 142 5.3 Engineering for the Masses 145 5.4 Critical Assessment of the New Industrial Revolution 146 Bookmark Chapter 5 154 References 155 About the Authors 160 Index 162 6 Foreword by Philippe Charlès, CEO DELMIA – Dassault Systemes Group For manufacturers, global competition has become increasingly fierce due to recent economic declines. Companies should embrace this situation as an opportunity and even a directive to rethink the way that products are developed and manufactured. Research carried out by the Aberdeen Group shows that over 85 percent of product costs are incurred in the pre-manufacturing phase, product design being the single greatest expense. Another finding is that there are three main reasons for develop- ment failure: • a product cannot be manufactured • components are not ready for production ramp-up • competition got in first. This means that innovation is imperative; not only at the technology level, but in every aspect of the product development cycle. Further research by Proudfoot Consult- ing demonstrates that 37 percent of time spent at work is unproductive, 75 percent of this part being due to the many difficulties companies experience around their operational management system. The major barrier to improving productivity is related to efficient planning and controls, which have declined over the last 4 years to arrive at 46 percent. Both surveys lead to the conclusion that companies should focus more on effec- tive means to reduce manufacturing costs and to better plan their activities. Digital manufacturing and simulation are the main enablers for obtaining such benefits. Digital manufacturing is the capability to define and simulate exactly how a prod- uct will be built in a global collaborative environment. Digital manufacturing allows production engineering staff access to product design at an early stage and also provides a clear view of the production environment. This results in better planning and validation of manufacture processes before a product is built. Simulation is key to many business operations, and its application is still devel- oping at a rapid pace. Today simulation ranks amongst the highest valued business techniques, and is supported by modern mathematics, by information technology and by computer graphics, to create a 100 percent lifelike experience. By being able to reliably plan, define and simulate the events of any conceivable scenario – from materials and weather conditions to complex manufacturing and business processes – collaborative production solutions can be worked out at a speed 7 that was hitherto unknown. The combination of traditional computer-aided design simulations with business process flows has now begun to merge into a new form of digital manufacturing. The book you are about to read covers these exciting possibilities and their accom- panying challenges. Modern digital manufacturing and simulation offer new oppor- tunities to efficiently and effectively conduct profitable business in ways that, even a few years ago, could only have been dreamt of. In the near future, lifelike experience and extended digital manufacturing will be at the very heart of any state-of-the-art manufacturing industry. Philippe Charlès CEO DELMIA– Dassault Systemes Group 8 Foreword by Luc-François Salvador, Chairman and CEO of Sogeti The book in front of you is important for several reasons. Obviously the book is an artifact of Sogeti’s relentless drive to work “smarter” and to enhance productivity. The High Tech activity of Sogeti is passionately involved in the digital support and guidance of engineering and manufacturing activities. We are privileged partners in a number of key processes and innovations