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Transcript of Virtual Manufacturing Anna Chernakova. 2 Biomedical U.S. Manufacturing – Global Leadership Through...
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Virtual Manufacturing
Anna Chernakova
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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
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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
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There’s 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
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DFM, 2010 5
/
Rome,1000BC – 550AD
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DFM, 2010 6
Italo Gismondi
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Plastico di Roma Antica 1933-19711:240
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Bernard Frischer
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Rome Reborn
1997-2007
Institute for Advanced Technology in the Humanities, UVUCLA 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
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http://earth.google.com/rome/
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Biomedical
Intro to VM
The next revolution in manufacturing.
Biomedical
3D MODELING,
SIMULATION
MANUFACTURING
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VM benefits Reduce development and
manufacturing cost
Reduce time-to-market
Enhance communication
Enhance Yield
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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
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Biomedical
Industry Case Studies
Automotive (Ford)
Aerospace (Boeing, AAI)
Electronics (Mentor Graphics)
Microelectronics (IBM)
Data Storage (Seagate)
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Ford
The next revolution in global manufacturing
AerospaceAutomotiveBiomedicalElectronics
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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.
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Ford: ROIProducts
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.
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Ford: Advanced 3D modeling
The next revolution in global manufacturing
AerospaceAutomotiveBiomedicalElectronics
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Ford: Virtual Environment
Programmable Vehicle Model
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Ford: Improving quality through VM
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Ford: Virtual ChecklistFinding problems before the physical build
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Boeing: Simulating the
entire assembly process
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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
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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.”
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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 prototype’s propeller, fuselage, etc.
AAI Corporation
Challenge
Improve AAI’s competitive position in the unmanned aerial vehicle (UAV) marketplace.
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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
• 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
AAI Corporation
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Biomedical
Electronics: PCB
Biomedical
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Biomedical
PCB and Mentor Graphics
Biomedical
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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 .
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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
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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.
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How Does It Work?
ViewerModeler
ProcessFile
2.) CAD Layout
1.) Parameterized Process Description
3.) Modeler combines Process and CAD inputsto emulate the device
4.) Use the Viewer module to view the emulated device in 3-D
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MEMS (micro-electro-mechanical systems)VM
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Seagate: Building Virtual Product&Process
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Seagate:
II. Magnetic head
- >1000 steps- ~ semicon process- complex
I. Slider
- few steps- highly critical
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VM – Slider
Design
-Direct savings of $500K annually in direct labor cost .
- Indirect savings due to drastic reduction of design errors.
ROI:
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VM flow
Model
Optimization
Model
Verification
3D model
(application) specific
Process-aware
Design
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VM Example
Process
Variations
Simulation
3D Model
Design for
Manufacturing
Design Rule Checks
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Select Design Type
(Full factorial, RSM, etc)
Define Actual Input Parameters
DOE1 DOE 2 …. DOE n
Model 1 Model 2 ….. Model n
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DOE generator
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Critical Target(s)
Input parameters
DOE Generator
Virtual Model Virtual Model Library
Data Analysis
Virtual metrology/DRC Real process/device metrology
CTOpt= TF (IPOpt)
Real process/device
Virtual Model Calibration/Validation
Target Verification
Input Distribution
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Virtual Optimization
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Biomedical
VMS
Biomedical
3D MODELING,
SIMULATION
MANUFACTURING
Virtual experiment
s generator/Optimizer
DFM
DRC
DFT
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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
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US Council on Competitiveness and VM
“Grand Challenge Case Study: Vehicle Design.”Full Vehicle Design Optimization for Global Market Dominance
Requirement Categories Computational Method
Body Styling 3D Full Body Computer Aided Design
Crash Worthiness 3D Dynamic Structural Deformation Analysis
Vehicle Structural Integrity Finite Element Structural Analysis
Fuel Efficiency Computational Fluid Dynamics
Passenger Comfort (Noise and Vibration) Acoustics and Finite Element Analysis
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Council on Competitiveness Case Studies and VM
“Grand Challenge Case Study: Vehicle Design.”
Multiple, independent simulations Single, integrated model
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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
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Council on Competitiveness Case Studies and VM
“Challenge Case Study: Auto Crash Safety”
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Virtual Manufacturing
Prototype the future: one in which virtuality will change
and enhance the way we work and live.
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Backup slides
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“No Defect “ Design
Misalignment
DOE Generator
81 virtual models
Automatic Error Detection
No defect
Change Design
Visual inspection & Analysis Defect
DFM, 2010 50
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DFM, 2010 51
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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