realization for future smart manufacturing engineering · construct flexible manufacturing system...

Realization for

Future Smart Manufacturing Engineering

实现未来型智能生产技术 미래형 Smart 생산기술 구현

Manufacture Engineering Department

Technical Seminar

Design Production Engineering Consulting DPECO CO., LTD2 / 48

DPECO Co., LTD.

1. Development TargetContents

2. Changing Technological Environment

3. Digital ProductionEngineering

4. DPECO’s DigitalProcess Engineering

5. Summary

Design Production Engineering Consulting 3 / 48

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1. Development Target

开发目标

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Development Target 开发目标

Delivery交货期

Quality质量

Productivity生产性

Cost成本

Life 生命

Survival 生存

Impression 感动

Competitiveness 竞争性

HOW ?

• Reduce development time by minimizing design

change and reducing tooling lead time.通过最小化设计变更及缩短工装生产周期，缩短开发周期설계변경최소화및 Tooling 기간단축을통한개발기간단축

• Save investment costs through feasibility study.

(Man, Machine, Material, Method)通过可行性分析，降低投资成本（人、机器、材料、方法）

• Meet quality target early by minimizing quality

deviation and stabilizing quality.通过最小化质量波动及质量稳定，早期实现质量目标품질산포최소화및품질안정을통한조기에품질목표달성

• Digital Manufacturing Engeering(Smart factory)

- Optimization for 4M数字化生产技术（智能工厂）优化 4M

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SE Engineering

同步工程 Reduce Pilot Leadtime

减少试生产时间 생산시간절감

Reduce Lead time for Ramp Up

减少爬坡时间 launch시간절감Advanced Verification

提前进行验证 사전검증실시 Digitalization

数字化 Digital화

TIME 时间 Advanced Prevention for Issue

提前预防预防 문제점사전예방

Material Saving

降低材料费 재료비절감 Reduction HPV

减少工时 공수축소

Minimize Prototype Car

尽量减少样车数量

Reuse and Optimize Equipment

设备再利用及优化 설비재활용,최적화

COST 成本

Advanced Approach for Lead Time , Investment and Efficiency

谋求时间、费用和效率的提高시간, 비용그리고효율에관한 향상추구

Optimization for 4M

4M的优化 4M의최적화

Knowledge based 建立知识基础 지식기반구축

Common Information

信息共享 정보공유 Construct Flexible Line

多个车型生产线 다차종라인 Digital Production System

数字化生产系统

Efficiency 效率

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PILOT #1

试生产#1


Problem trending curve in the vehicle development time车辆开发期间出现问题曲线 차체개발기간중의문제점발생추이

Vehicle Development Process车辆开发过程

Major Investment Season

重要投资时期

Problems Issue

发现问题时间节点的早期化

Th

e n

um

be

r o

f is

su

es

问题

件数

Planning

企划Prototype Tooling

样车制作Design

设计Production

ToolingPILOT #2

试生产#2SOP

量产

After design review

以进行S.E活动早期发现问题

Critical issues must be closed before major investment (Facility, Mold etc.) season.

重大投资前必须关闭关键问题点（设备/模具等）

General development

在一般的开发方式下发现问题的曲线

Reduce problems

at production readiness phase

减少生产准备阶段的问题点

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Concept

概念

Design

设计

Test/Tooling

试验/设备

Pilot Production

试生产

SOP

量产

0

20

40

60

80

100 (%) Determination ratefor Cost

成本决定率85%

95%

Cost occur rate成本发生率

80%

20%

5%

Cost Saving Opportunity

降低成本的可能性

SE/Process Engineering

SE/工艺

Key Factor for

Cost Saving成本节减重要领域원가절감중요영역

Man 人

Material 材料

Machine 机器

Method & Others

方法及其它

Cost Trend for Each Product Development stage 产品开发各阶段的成本变化曲线 제품 개발 단계별 원가 추이



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2. Changing Technological Environment

技术环境的变化 기술환경의 변화

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Advanced R&D strategy of each Country 각나라의 선진화 R&D정책

各国的先进化R&D政策America

美国`

Advance Manufactu-ring Technology

(Making in America)

2,9 Billion USD(2014 year)

• Feb. 2012 : National strategyplan for high tech manufacturing system2012年2月国家尖端制造方式

战略计划• Jul. 2012 : Recycle plan for

Manufacturing industry7月制造业可再生规划

-2012년2월 국가첨단 제조방식 전략계획-7월 제조업 재생계획

• Strengthen Competitiveness加强竞争力• Better Job Creation创建美好的工作岗位

• Nation Security 国家安全等

경쟁력강화/ 좋은 일자리 창출국가안보등

Country

国家

R&D

Program

R&DInvestme

nt

Basic

Strategy

基本战略

Back

ground

背景

Germany德国

Industry 4.0

0.2 Billion Euro(2014~2015 year

)• 2010: High-Tech Strate-

gy to 20202010年-尖端技术战略2020• 2012 : Action Plan2012年执行计划

-2010년 :High-Tech Strategy2020

-2012년 실행계획

• Economy Growth经济成长

•Job Creation创建美好的工作岗位• Aging Society/Climate

change高龄化、气候变化等

경제성장/일자리 창출고령화 /기후변화등

Japan日本

StrategicInnovation

51 Billion Yen(2014 year)

• Jun. 2013: Revival Planfor Japan Industry2013年6月日本产业复兴

计划

2013년6월 일본산업 재흥플랜

• Science, Technologyand Innovation科学技术革新•Strengthen industrialbase加强产业基础

과학기술 혁신산업기반 강화

Korea韩国

Industry Innovation3.0 – 3 core

strategy制造业革新 3.0 3大战略제조업혁신 3.0 3대전략

1 Billion USD(~2020 year)

• Create Convergence New • Manufacturing Industry创建融合型新制造业• Strength Core Value for • Major Industry加强主力产业核心力量• Upgrading Manufacturing Innovation Fundamental制造革新基础尖端化

-융합형 신제조업 창출-주력산업 핵심역량강화- 제조혁신기반 고도화

China, India中国、印度

* China 中国:• China 2025 Strategy for

Manufacturing --As growth the Major 10field, Secure Competitiveness with Germany and Japan中国制造2025战略

通过培育新产业10大领域，保证德国、日本水平的竞争力중국제조2025전략신산업 10대분야 육성을 통해 독일일본수준의 경쟁력 확보

* India 印度: •Based on 1.2 Billon People and software power, propel“Make in India” to makeJob Creation -100 million job以12亿人口和软件强国为基础，推进“印度制造”，创建1亿个制造业领域工作岗位12억 인구와 소프트 파워를 바탕으로“Make in India”추진 제조업부문 일자리 1억개 창출

Smart SE

SmartProduction Engeering

Smartfactory

(Reference): Minstry of Trade,Industry and Energy

产业通常支援部门산업통상자원부

◆ Future national competitiveness through innovation in manufacturing industry.通过制造业革新，保证未来国家竞争力제조산업혁신을통한미래국가경쟁력확보

(Reference):Hyundai Research Institute

现代产业研究院 현대산업연구원

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Changing Automotive Industry Environment

How to satisfy Customer 顾客要求的满足条件

Diversificationof Customer Demand

顾客要求的多样化

Market is Driven by Customer

고객주도형시장으로전환 转换为顾客主导的市场

Create Rapid Design to Market Demand 迅速地创造根据市场要求的造型 시장의요구에따른신속한디자인을창조

Shorten New Car Development Period缩短新车型开发周期 신차종개발기간의단축

Construct Flexible Manufacturing

System 建立灵活的设备項目 유연한설비 System의 구축

Minimize Issue during Development Process尽量减少开发过程中的问题 개발과정에서의문제점최소화

Construct Multi Model Production System确保多车型生产項目 다차종생산 System 확보

Saving Investment 减少投资费用 투자비용의절감

Part Commonization at Development Stage 零件开发的共用化及泛用化 부품개발의공용화및범용화

Reduce Mass Production Vehicle대량생산차량의감소 减少大量生产车型的种类

Reduce Profit on sales매출대비이익률의감소 减少销售对比利益率

Requirement for High Quality고품질의요구 要求高质量

Increase Module ProductionModular 생산방식의확대 扩大模块生产方式

汽车制造业的环境变化 자동차산업의 환경변화

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Competition for reducing New car development Period新车开发周期的竞争 신차 개발기간의 경쟁

50 40 30 20 10Time-to-Market (Month)

Gen

era

tion

时代

2

3

Current 现在

1

24 ~ Month(月)

36 ~ 24Month(月)

48~36Month(月)

50%

Changeover

交替时间

75%

(Reference): McKinsey Survey (Insight Manufacturing)

Easy

容易Engineering

Improvement

技术发展

Digital

Engineering

数字化技术

As re-introduction of Optimized Current System, Accleation for Quality Level and Speed.通过再引进优化性的现有体系，提高质量和速度기존 최적화된 시스템 재도입으로 품질과 속도의 향상

(Reference) :Wall Street Journal & U. of Michigan, Management Briefing Seminar

Downtime

中断时间

Productivity

生产性

70%缩小缩短


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FMS Line (共用化生产线)

Production period 生产期间

Vo

lum

e

生产台数

Amodel

Bmodel

Cmodel

Exculsive Line专用线

Stop

停产

Production period 生产期间

Vo

lum

e

生产台数

A

model

B

model

Cmodel

Stop

停产

Efficiency for Operator Distributionis poor 操作人的编排率较低 (生产性)

Addition Space for New car Development 需要按新车型展开的另外的地点

Initial Investment is Low,but Total Investment is more higher初期投资费稍微便宜，但是综合成本较高-작업자편성율저하 (생산성).-신차종전개에따른별도전개장소필요.-초기투자비는다소저렴하나. 종합 Cost는고가임

MixedFMS Line

(混线)

Production period 生产周期

Vo

lum

e

生产台数

Amodel

Bmodel

Cmodel

Through Automation, Achieve man power reduction通过采用自动化可以省力

Initial Investment is high, but Total Investment is lower初期投资费较高，总体而言设备投资费较便宜-자동화로성력화가능.-초기투자비는고가이나, 종합적으로. 설비투자비는저렴함.



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3. Digital Production Engineering

数字化生产技术

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Digital(3D Tool) World 数字化(3D Program)世界

Playground

development

开发的广场

Digital(3D) Tool World 数字化(3D)工具世界

DelmiaAutocadCatia Autoform DynaformUG ALIASRobocad3D VIA

ENOVIA SOLID WORKSSIMULIA 3DCS ABAQUSQuest VSA Draft Sight

3DS MAX

Process Engineering 生产技术

Design

设计

Production LineDeployment

生产线开展

PilotProduction

试生产

Sales销售

MassProduction

量产

ProductPlanning

商品规划

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Digital Production Engineering 数字化生产技术

Digital Design

数字化设计

Digital Production

Engineering


DigitalManufacturing(Smart Factory)

数字化制造(智能工厂)

Readiness Stage for Smart factory

为了达成智能化工厂的准备过程

Production Readiness using Digital

Tool

应用数字化工具的生产准备

Through Simulation, Verification

for Production system and

Product Design

通过模拟，验证产品设计及生产系统

-Smart factory로가기위한 준비과정-Digital Tool을활용한생산준비-Simulation을 통해제품설계및생산system검증

3D Design using Digital Tool

应用数字化工具的三维设计

Design possible for

Reliability Verification

可以进行可靠性验证的设计

-Digital Tool을활용한 3차원설계-신뢰성검증이가능한설계

Intelligent Factory in which all

component and system is connected

by IT (the 4th Industrial Revolution)

将工厂内所有要素及系统连接为IT的

智能型工厂（第4次产业革命）

All Automatic Production System

完整的自动生产体系

Optimized Production Process生产过程的最优化

Intelligent overall work process所有操作过程的智能化

-공장내의모든요소및 System을 IT로연결한지능형공장 (4차산업혁명)-완전한자동생산체계/ 생산과정의최적화-모든작업과정지능화/

Process Engineering 工艺设计

Design

设计


生产线开展

PilotProduction

试生产

Sales销售

MassProduction

量产

ProductPlanning

商品规划

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Digital Manufacturing

(Smart Factory)

数字化制造（智能工厂）Digital Production

Engineering

数字化生产技术Digital Design 数字化设计

Needs(PQCD) 需求

Reduce New car Development

Period 新车型开发期间的缩短신차종개발기간의단축

Minimize the Issue During Developing

Timing 开发过程的问题点最小化개발과정에서의문제점최소화

Apply Flexible Manufacturing Line

多个车型生产系统保证다차종생산 System 확보

Saving Investment

投资费用的节减 투자비용의절감

Reliability可靠性신뢰성

Verification for Product Design

(Design Review)

产品设计验证（DR）제품설계검증(DR)

Verification for Manufacturing

Process 制造工程验证제조공정검증

Real time Analysis for Static and

Dynamic 实时的静态、动态验证실시간정적/동적검증

Digitalization of Process Planning

工艺的数字化 공법의 Digital화

Application Area适用领域

SE & Process Stage

SE/工艺领域 공법영역

Off-Line Programming 离线编程

Optimization Review for 4M 4M的优化4M의최적화

Simulation for Productivity and

Workability생산량및작업성 Simulation

产量及操作性的模拟

Material Flow Simulation

物流模拟 물류 Simulation

Integration Production Control Center

和生产系统信息互换생산System과정보호환

Process Engineering 工艺设计

Design

设计


生产线开展

PilotProduction

试生产

Sales销售

MassProduction

量产

ProductPlanning

商品规划


DPECO Co., LTD.

4. DPECO’s Digital Process Engineering

DPECO的数字化工艺设计

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DPECO’s Digital Process Engineering(Sample)

ProductPlanning

商品规划

Design

设计


生产线开展

PilotProduction

试生产

Sales销售

Process Engineering

MassProduction

量产

Smart Process forBody Engineering焊装工艺的智能化

▪ SE

▪ Process Planning 工艺规划

▪ Verfication 验证

▪ Lay Out 平面布置

▪ Simulation 模拟

▪ Optimization 优化

Digitalization of Dimensional Engineering尺寸工程的数字化

▪ DTS Design & Validation DTS 设计及验证

▪ DTS Tolerance Relation(QFD)DTS 公差尺寸链分析(QFD)

▪ 3D RPS(MCP), GD&T▪ 3D Tolerance Deviation Analysis3D 公差偏差分析(3DCS)

▪ 3D C/F Specification 3D C/F 式样书

Smart Process forG/A Engineering总装工艺的智能化

▪ SE

▪ Module Study 模块化分析

▪ Tool Catalogue 工具库

▪ Line Simulation 生产线模拟

DPECO的数字化工艺设计（模板）


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Dimensional Engineering

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DPECO Co., LTD.Digitalization of Dimensional Engineering 尺寸工程的数字化

4M Analysis4M分析

Benchmarking Car Analysis 競争車分析

Marketability Analysis 商品性分析

Section Structure Analysis 断面構造分析

Design MCP, GD&T Utilizing Catia Data. 将MCP,GD&T应用在Catia数模上。

* DE ＝ Dimensional Engineering* DTS＝Dimensional Technical Specification* QFD = Quality Function Development

* 4M = Man, Machine, Method, Material

Adjust DTS调整DTS

NO

Evaluation评价

Confirm确定

DTS Design & Validation DTS 设计及验证

1

DTS Tolerance Relation(QFD)DTS公差链分析(QFD)

2

RPS(MCP)Drawing

RPS(MCP) 设计

3D GD&T Drawing

3D GD&T设计

3

3D Tolerance Deviation Analysis3D 公差偏差分析

3D C/F Master Plan

3D 检具构思图

3D Check Point Drawing

3D 检测点设计

4

Inspection Report

检测报告

NO OK

OK

NO

OK

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Digitalization of Dimensional Engineering 尺寸工程的数字化

Benchmarking Car Analysis标杆车分析

CAS, M/Section AnalysisCAS,主断面分析

NO

OK

Competitive Car Analysis 競争車分析

Marketability Analysis 商品性分析

Section Structure Analysis 断面構造分析

Evaluation评价

DTS Validation DTS验证

NO


Evaluation评价

Confirm确定

RPS(MCP)Drawing

RPS(MCP) 设计

3D GD&T Drawing

3D GD&T设计

2

3


3D C/F Master Plan

3D 检具构思图


3D 检测点设计

4

Inspection Report

检测报告

NO OK

OK

NO

OK


Design Competitive Vehicle

Interior/Exterior DTS.设计有竞争力的整车内外观DTS。

1

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1. DTS Validation DTS 验证

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Decision of DTS Tolerance 决定DTS公差

OK

NO

Evaluation评价

QFD DevelopmentQFD展开

DTS Tolerance AnalysisDTS公差链分析

NO

QFD=Quality Function Deployment质量工程展开

OK

QFD Analysis Sheet***

Tolerance Relation Sheet***

NO

Evaluation评价

Confirm确定

RPS(MCP)Drawing

RPS(MCP) 设计

3D GD&T Drawing

3D GD&T设计

1

3


3D C/F Master Plan

3D 检具构思图


3D 检测点设计

4

Inspection Report

检测报告

NO OK

OK

NO

OK



Verify Vehicle DTS & Datum Location

验证整车DTS及定位基准

2

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2. DTS Tolerance Relation (QFD ) DTS公差链分析(QFD)

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3D Tolerance Deviation

Analysis Report3D公差偏差分析Report

OK

NO

RPS(Datum,MCP) Analysis **分析

3D Tolerance DeviationAnalysis 3D公差偏差分析

Evaluation评价

RPS(MCP)DrawingRPS(MCP) 设计

3D GD&T Drawing3D GD&T 设计

NO


Evaluation评价

Confirm确定

1

2

3D C/F Master Plan

3D 检具构思图


3D 检测点设计

4

Inspection Report

检测报告

NO OK

OK

NO

OK


RPS(MCP)Drawing

RPS(MCP) 设计

3D GD&T Drawing

3D GD&T设计


Design Datum & Tolerance Drawing

Utilizing 3D Tools and Execute Verification.使用3D软件编制定位及公差相关的资料后进行验证

3

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3. 3D Location & Tolerance 3D 定位及公差

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NO


Evaluation评价

Confirm确定

RPS(MCP)Drawing

RPS(MCP) 设计

3D GD&T Drawing

3D GD&T设计

1

2

3


NO OK

OK

NO

OK


3D C/F Master Plan

3D 检具构思图


3D 检测点设计

4

Inspection Report

检测报告

3D C/F Master Plan3D 检具构思图

3D Check Point Drawing3D 检测点设计

Inspection Report检测报告

Design 3D Measurement Method

to Guarantee The Vehicle Quality.设计3D检测方法，以保证整车质量

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4. Vehicle Measurement Planning 整车检测计划


DPECO Co., LTD.

Body Process Engineering

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1. Design Review

-CAS-Clay Model

-Master Section-Product Design

-Proto Type Car

1. Flow Chart

2. 3D MCP3. Weld LayOut

4. Weld Gun Study5. Time Chart

1. Pre Simulation

2. Work Area

3. Work’g Height4. Interlock

1. Arrangement

2. Logistics3. Equipment

4. Ergonomics5. 4M Optimizing

1. Sequence

2. Cycle Time3. Solution

4. Payload5. Off Line Program

6. Calibration


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LAY OUT

&OPTIMIZING

VERIFICATIONSIMULATION

&OLP

PROCESS

PLANNINGDESIGN

REVIEW


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&OLP

PROCESS

PLANNING

LAY OUT

&OPTIMIZING

DESIGN

REVIEW

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&OLP

PROCESS

PLANNING

LAY OUT

&OPTIMIZING

DESIGN

REVIEW

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VERIFICATIONPROCESS

PLANNING

SIMULATION&

OLP

LAY OUT

&OPTIMIZING

DESIGN

REVIEW

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&OLP

PROCESS

PLANNING

LAY OUT

&OPTIMIZING

DESIGN

REVIEW


DPECO Co., LTD.

Assembly Process Engineering

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1. DMU Check

2. Dynamic Sectioning3. Tool Catalog

4. Concern And Reason

5. Countermeasure

and Proposal

1. Assembly Element

Description2. Insert Order Entry

and Quantity3. Insert Man-hour

Assembly Time

4. Importance Management

Property

1. Item Selection Optimization

2. Composition List up3. Flow Chart

1. Product and

Component Modeling

2. Equipment Modeling

3. Sub Part Process

Detail Modeling4. Process Assembly

Simulation

1. Line Process Layout

2. PPR Linkage

Platform Build Up

3. Sequence andCycle Time Apply

Analysis

3. Solution CombineProcess Simulation


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Sub PartAssembly Simulation

ModularizationLayout Analysis

Simulation

Vehicle Assembly Manual

DESIGN

REVIEW


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ModularizationLayout

Analysis Simulation


DESIGN

REVIEW


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Analysis Simulation

DESIGN

REVIEW

Vehicle

Assembly Manual


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AnalysisSimulation

DESIGN

REVIEW



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AnalysisSimulation

DESIGN

REVIEW




DPECO Co., LTD.

Advantage of DPECO Special ProgramDPECO 专用程序的优点

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Advantage of DPECO Special Program DPECO 专用程序的优点

Section 区分 Dpeco Program Dpeco 程序 Increased productivity 提高工作效率

DTS Tolerance

Analysis

D- Tolerance Tool90 Days

30 Days

0

30

60

90

Existing Program DPECO Program

☜Productivity up 300%-Analysis based on

50 points

3d MCP

D- MCP Tool80 Days

40 Days

0

20

40

60

80



1 Body development

D- Flow ChartTool

Flow Chart

45 Days

15 Days

0

15

30

45



1 Body development

3d Weld

Lay Out

D-ProcessTool80 Days

60 Days

0

20

40

60

80



1 Body development

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DPECO Co., LTD.

Advantage of DPECO Special Program DPECO 专用程序的优点

Section 区分 Dpeco Program Dpeco 程序 Increased productivity 提高工作效率

Weld Gun

Verification

D-Weld Gun Tool80 Days

40 Days

0

20

40

60

80



1 Body development

Digital Pre

Assembly

DPA

-Use Delmia DPA

150 Days

70 Days

0

50

100

150

Existing Program(Catia DMU)

Delmia DPA


1 Vehicle development

COST SAVING(Section: Process Design)

USD 108,000 / Vehicle

成本降低（工艺阶段）


DPECO Co., LTD.

5. Summary 整理

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DPECO Co., LTD.

.

Summary 整理

Productivity 生产性

Quality 质量

Cost 成本

Delivery 交货期


Changing Technological Environment

技术环境的变化 기술환경의 변화

Advanced R&D strategy of each Country 各国的先进化R&D政策 각나라의 선진화 R&D정책

Competition for reducing New car development Period新车开发周期的竞争 신차 개발기간의 경쟁

As re-introduction of Optimized Current System,

Accleation for Quality Level and Speed.

通过再引进优化性的现有体系，提高质量和速度기존 최적화된 시스템 재도입으로 품질과 속도의 향상

Digital Design 数字化设计


Digital Manufacturing (Smart Factory) 数字化制造(智能工厂)

Digital Production Engineering


Digital

World

Thank You!

47-7, Gongdan-ro 140beon-gil, Gunpo-si, Gyeonggi-do, Korea T. 82-31-688-1500 F. 82-31-441-7626 www.dpeco.com

realization for future smart manufacturing engineering · construct flexible manufacturing system...

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