3D Manufacturing Facility and Production Line Capture

Size: px

Start display at page:

Download "3D Manufacturing Facility and Production Line Capture"

Lawrence Johns
5 years ago
Views:

SPAR 2004 Symposium May 19, 2004 3D Manufacturing Facility and Production Line Capture Presented

1 SPAR 2004 Symposium May 19, D Manufacturing Facility and Production Line Capture Presented by: Bill Campbell GM Vehicle Operations Competitive Operations Engineering Mike Ryan GHAFARI Companies

2 SPAR 2004 Symposium May 19, 2004 Agenda History / Pilot Activities 2D to 3D layout data migration strategy Plant Model Flythroughs Business Impact Future Challenges Questions & Answers

3 3D Plant Layout Development History : 3D Plant Layout Assessment / Development Assessed current technology (FactoryCAD 5.x, others) Defined pros/cons, developed requirements / project plan Delivered functional requirements to EDS/PLM to enhance FactoryCAD, Unigraphics and ProductVision : 3D Plant Layout Pilot initiated at Lansing Grand River Assembly Plant Developed / validated UG to AutoCAD translation process Tooling and Product data Developed Data Creation Standards,Business Processes and Training Material Piloted 2D to 3D data migration approach Evaluated / Piloted 3D Laser Scanning Technology - GM Business Case defined and validated Notice of decision to deploy 3D plant layout processes and tools across All North American Assembly Plants and Future Program Projects Current: Forecasted to have remaining GM Assembly plants & future Programs converted to 3D by end of Defining Global Migration Approach

4 3D Plant Layout 2D to 3D Data Migration Applications UG to AutoCAD data tessellation process Manufacturing 3D AutoCAD Block Library Capturing / Modeling Current Plant Conditions 3D Plant Layout Examples / Flythrough

3D Layout Business Vision Capture as-builts Laser scan areas of plant that

Author 3D layouts - Use parametric & static design objects in ADT 3.

1 Integrated UG data - Insert 3D product & tooling data directly into

5 3D Layout Business Vision Capture as-builts Laser scan areas of plant that will be impacted by future product/production changeovers. Author 3D layouts - Use parametric & static design objects in ADT 3.3 /AutoCAD & Factory CAD 7.1 Integrated UG data - Insert 3D product & tooling data directly into layout after preparing UG data for translation Conduct 3D layout reviews - Navigate through integrated layout or specified areas utilizing ProductVision

6 UG to AutoCAD Translation Process 1. Original UG Tool Assembly: File size 40.7 MB 2. After simplification: UG Envelope File size 6.13 MB 3. UG Envelope after JT Tessellation Process: File size MB 4. AutoCAD.dwg Block (3D and 2D views, excluding bottom) size MB

7 3D Plant Layout Block Library Approx Blocks developed Block Management Utilizing Autodesk s Web Based idrop Technology Consists of both AutoCAD objects and XML

2D to 3D Plant Layout Data Migration Process Flow Overview GM Project Team (HQ) 3.

GHAFARI Project Team (Plant) 1. GM identifies areas of plant to model that are impacted by new vehicle program. 2.

3D Modeling Team (HQ) 3D Laser Point Cloud 2D Plant Layout File 5. 3D modeling team electronically submits 3D CAD model and all data submitted by scanning vendor to GM (Plant) for review and buy-off.

8 2D to 3D Plant Layout Data Migration Process Flow Overview GM Project Team (HQ) 3. Scan Team scans area(s), takes digital photos/video and electronically submits scan, photos/videos and 2D data along with FCO to 3D modeling team. Note: 2D layout depicts photo ID s and locations. GHAFARI Project Team (Plant) 1. GM identifies areas of plant to model that are impacted by new vehicle program. 2. GM submits field check request to GHAFARI identifying areas to be scanned with LOD requirements. 2D layout data is also submitted at this time for reference purposes. 3D Modeling Team (HQ) 3D Laser Point Cloud 2D Plant Layout File 5. 3D modeling team electronically submits 3D CAD model and all data submitted by scanning vendor to GM (Plant) for review and buy-off. GM Project Team (Plant) 7. GM Plant reviews and validates 3D model and submits layout(s) to GM Central Layout Group. Plant maintains plant layout in 3D as mainstream process. Digital Photograph(s) 4. 3D Modeling team loads scan point cloud data and overlays FactoryCAD objects, UG tooling / product data producing completed 3D CAD model. 6. GM validates 3D model against plant conditions. If inaccuracy issues are identified, GM modeling teams rectifies 3D layout and submits to plant for review and ownership.

9 3D Plant Layout Data Acquisition Laser Scanning Process 1 Develop Area s of Concern Layout and highlight level of detail. 2 Determine scan envelopes, elevation references, and avi capture. 3 Scan area & generate 3D point clouds. 4 Register individual point clouds to compile overall scan world. Scan 1 Scan 2 Compiled point clouds

10 3D Plant Layout Data Migration Modeling Process Insert Point Cloud into AutoCAD. 1 2 Use Point Cloud as template to place ADT/FactoryCAD/UG Tooling Objects into layout. Remove point cloud from AutoCAD file. 3D CAD model complete. 3 4 Enables Modelers at Project Center (HQ) to view and hear Markup comments from Field Check Engineers. Reduces Field Markup errors / interpretation issues. Also reduces field check time required to write down issues on layout. Visualization file created and used by plant for layout validation / buy-off.

11 3D CAD Modeling Process Utilizing Point Cloud & Parametric Technology 3D CAD Model of the Lansing Grand River Framing Line. Created using ADT 3.3, FactoryCAD 7.1 parametric objects. AVI Created with ProductVision 4.0

12 3D Layout Body Shop Visualization

13 3D Laser Scanning Un-Measurable Benefits 3D laser scanning offers high level of accuracy (6mm over 100 ft.) Eliminates human error, increases accuracy Captures multiple engineering discipline equipment that can be shared thus reducing redundant field checking in same area. Less CAD modeling time required. CAD operator uses 3D point cloud file as template. No need to refer to field markup hard copies to measure / layout CAD model. (Major time savings). Elimination of interpretation errors from field check data generated from field check engineer and 3D CAD modeler Enables CAD modeler to use same information to model Building, conveyor, process equipment and material / workplace layouts. Reduction in Field Change Orders Enables ME / IE/ WFG business sectors to references point cloud data file into layouts and design around other business sector s fixed / permanent monuments that would cost major $$$ in field change orders to rectify - (Cost Avoidance)

14 3D Plant Layout Business Impact Faster Layout Development - Est. 30% Productivity Gain Sections, elevations details created / maintained semiautomatically Bill of Materials auto generated and maintained Factory CAD & ADT functionality reduces time to create layouts compared to manual 2D methods Improved Tool Installations & Startup - Est. 15% Field Order Reductions. Live 3D Layout reviews: Robust cross functional reviews Fewer Iterations Interpretation errors drastically reduced Detect/Correct Errors in Math --> Fewer late changes at plant (cost avoidance). Parametric Smart Objects - Follow GM Design Rules for Safety, Speeds Design Process

3D Plant Layout Future Challenges As Installed Data Integrity

Keeping Current with the Pace of Change in the Plant Speed of Data Acquisition

15 3D Plant Layout Future Challenges As Installed Data Integrity Warehousing/Distribution of Data Web Based Viewer to Measure and Mark-up Keeping Current with the Pace of Change in the Plant Speed of Data Acquisition Scan Time Point Cloud Registration Combine Laser Scanning / Photogrammetry Technology? Speed of CAD Modeling Conversion Utilizing Parametric Smart Objects Rather than Solids Object Library Auto Recognition Plant Floor Slab Variations / CAD Modeling requirements.

16 2004 Cadillac XLR

17 2004 Chevy SSR

18 2005 Cadillac SRX

19 2005 Hummer H3H

20 Thank You

CAD Comparison and Related Technology For Enhanced Digital Workflows

CAD Comparison and Related Technology For Enhanced Digital Workflows Thursday, November 16, 2017 Annalise Suzuki Director of Technology & Engagement Elysium Company Intro 30+ Years of CAD Expertise Strong