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Virtual Manufacturing Anna Chernakova. 2 Biomedical U.S. Manufacturing – Global Leadership Through Modeling and Simulation The long-term national and.

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Presentation on theme: "Virtual Manufacturing Anna Chernakova. 2 Biomedical U.S. Manufacturing – Global Leadership Through Modeling and Simulation The long-term national and."— Presentation transcript:

1 Virtual Manufacturing Anna Chernakova

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

3 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

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

5 DFM, / Rome, 1000BC – 550AD

6 DFM, Italo Gismondi

7 7 Plastico di Roma Antica :240

8 8 Bernard Frischer

9 Rome Reborn 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

10 10

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

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

13 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

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

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

16 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 Fords testing is done virtually, 5%-10% without a physical prototype.

17 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.

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

19 19 Ford: Virtual Environment Programmable Vehicle Model

20 20 Ford: Improving quality through VM

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

22 22 Boeing: Simulating the entire assembly process

23 23 Boeing: ROI 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

24 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.

25 25 and VM 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 prototypes propeller, fuselage, etc. AAI Corporation Challenge Improve AAIs competitive position in the unmanned aerial vehicle (UAV) marketplace.

26 26 and VM 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 Companys 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 AAI Corporation

27 27 Biomedical Electronics: PCB Biomedical

28 28 Biomedical PCB and Mentor Graphics Biomedical

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

30 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

31 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.

32 32

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

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

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

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

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

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

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

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

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

42 42 Biomedical VMS Biomedical 3D MODELING, SIMULATION 3D MODELING, SIMULATION MANUFACTURING Virtual experiments generator/Op timizer DFM DRC DFT DFM DRC DFT

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

44 44 US Council on Competitiveness and VM Grand Challenge Case Study: Vehicle Design. Full Vehicle Design Optimization for Global Market Dominance Requirement CategoriesComputational Method Body Styling3D Full Body Computer Aided Design Crash Worthiness3D Dynamic Structural Deformation Analysis Vehicle Structural IntegrityFinite Element Structural Analysis Fuel EfficiencyComputational Fluid Dynamics Passenger Comfort (Noise and Vibration)Acoustics and Finite Element Analysis

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

46 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

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

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 81 virtual models Automatic Error Detection PROCESSPROCESS No defect Change Design Visual inspection & Analysis Defect DFM,

51 DFM,

52 52 Council on Competitiveness Case Studies and VM Grand Challenge Case Study: Vehicle Design. Full Vehicle Design Optimization for Global Market Dominance Auto Crash Safety Study Crude Oil Catalysts Study Oil and Gas Recovery Study Textile Manufacturing Study


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