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

 

DFM, 2010 5

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Rome,1000BC – 550AD

 

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

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“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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Electronics: PCB

Biomedical

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PCB and Mentor Graphics

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Biomedical

Mentor's Valor MSS Solutions

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- 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

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

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

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

44

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”

 

Virtual Manufacturing

Prototype the future: one in which virtuality will change

and enhance the way we work and live.

 

Backup slides

“No Defect “ Design

Misalignment

DOE Generator

81 virtual models

Automatic Error Detection

No defect

Change Design

Visual inspection & Analysis Defect

DFM, 2010 50

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