Volvo Group Trucks Operations is a subordinate organization to the Volvo Group concern, which is one of the world's largest manufactures of trucks, buses, construction equipment, marine and industrial engines. Volvo Group Trucks Operations organization encompasses all production of the Volvo Group’s engines and transmissions as well as all production of Trucks. Volvo Group Trucks Operations is looking into digitize the methods utilized for information handling within their assembly plant in Tuve, Sweden, and this thesis project part in the digitization process.  The currently used assembly work instructions at the assembly plant in Tuve are printed on paper and contains excessive amounts of information that makes it challenging for the assembly operators to consume the work instructions efficiently. Therefore, Volvo Group Truck Operations want look into the possibility to introduce dynamically adjustable and digital work instructions that could be tailor fitted to an operator's experience level and presented with smart technologies. The project is divided into two parts where the first part was assigned to identify the information need for smart process capable of generating dynamic digital work instructions and the second part to research how this information need could be satisfied with currently used simulation tools. The information needs analyses showed that the smart process needs to be divided into two sub-processes, one for gathering and processing production specific data into a fully detailed work instruction and the other one for filtering the fully detailed work instruction to tailor fit an operator independent of their skill level within assembly work. A framework containing three information aspects is stated to describe the information need for the smart process. These information aspects are Inputs, Smart process and Outputs. The information aspects are then further broken down into five required information areas that is important for the smart process functionality. The required information areas are Data, Attributes, Inputs, Instruction and Information structure and Instruction consummation. When combining the results for the information aspects and the required information areas, the framework for the smart process needed to be able to generate dynamic digital work instruction could be stated. Using the simulation software IPS IMMA to simulate a generic assembly demo case to generate and export production specific data in the human readable XML coding language showed that it is possible to satisfy the framework for the smart process. However, comparing the simulated data with the information need for the framework resulted in the discovery that the IPS IMMA version used in the project, PMTS event exporter, withholds information regarding the assembly work. The generated data provides information regarding movement distances, movement times and grip types when interacting with work objects. For the smart process to be able to generate fully detailed instructions it needs to be supplied with additional information regarding the work objects in action and directions of movements conducted during the assembly work. Despite this withhold of information from the export data, it would still be possible to fully satisfy the framework for the smart process. All the missing information is contained within the IPS IMMA hence the software needs an update that adds the additional information to the data export.

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A manufatura virtual representa uma abordagem emergente que as empresas podem adotar para melhorar seus processos de desenvolvimento de produtos, introduzindo novos produtos no mercado mais rapidamente e a um custo apropriado. A ideia fundamental é criar um ambiente integrado e sintético, composto por um conjunto de ferramentas e sistemas de software, tais como realidade virtual e simulação para apoiar esses processos. O objetivo deste trabalho é analisar a utilização da manufatura virtual no processo de desenvolvimento de produtos em termos de limitações existentes que podem ser superadas, proposta da manufatura virtual, benefícios, e desafios encontrados para sua aplicação. Para a realização da análise, foi desenvolvido um modelo para orientar a aplicação da manufatura virtual no processo de desenvolvimento de produtos que considera: as atividades do desenvolvimento de produtos que podem ser apoiadas por sistemas de software da manufatura virtual; os tipos de sistemas e suas funcionalidades; e alternativas de formatos neutros para habilitar a interoperabilidade de dados. O trabalho foi desenvolvido através da realização de estudos de caso, que forneceram informações para a análise da utilização da manufatura virtual e para a geração do modelo proposto. / Virtual manufacturing represents the emerging approach the enterprises can use to improve their processes, introducing new products more quickly in the market in a cost effective way. The fundamental idea is to create an integrated and synthetic environment, composed of software tools and systems such as virtual reality and simulation to support those processes. The purpose of this work is to analyze the utilization of virtual manufacturing in the product development process regarding current limitations that can be overcome by virtual manufacturing, its proposal, benefits and challenges for its application. For the analysis accomplishment, a product development model in virtual manufacturing environment was developed which considers: the product development activities that can be supported by virtual manufacturing systems; the system types and their functionalities; and neutral formats alternatives to enable data interoperability. The research was done by the accomplishment of case studies that provided information to the impact analysis and to the model development.

O objetivo dessa pesquisa é responder à pergunta: Como as áreas de projetos e processos de empresas fabricantes de veículos automotivos podem se beneficiar dos softwares simuladores de montagem, durante as fases de projeto do produto e especificações dos processos a serem utilizados? O escopo desse trabalho está localizado na utilização de softwares de simulação virtual para análise das condições de montagem e detecção de possíveis interferências dos equipamentos de montagem durante o desenvolvimento de novos produtos. A validação deste trabalho será feita através da análise de dois estudos de caso. Para a coleta de dados serão realizadas entrevistas semi-estruturadas com a utilização de um roteiro para a pesquisa de campo, aplicadas diretamente aos usuários dos processos de simulação da Engenharia de Processos de Montagem de Veículos da General Motors do Brasil. De posse dos conceitos obtidos pela revisão bibliográfica e pela pesquisa de campo, pudemos analisar os benefícios técnicos e econômicos da adoção das simulações virtuais dos processos de montagem e confirmar a validade das proposições estabelecidas: contribuição para a redução de custos adicionais em equipamentos de montagem e o aumento da detecção de interferências dimensionais entre partes e equipamentos numa montagem, durante a fase de projeto. / The research objective is to answer what can be an assembly process strategy in automotive companies to make use of virtual simulation over development product phase. The scope of this study is to use virtual simulation to analyze the assembly condition and detect interferences between assembly equipment and product parts or components during development phase. In this report we studied two cases in order to register the facts. Thus, some interviews and a semi-structured questionnaire were answered for General Motors do Brasil software simulation users. Making an analysis with the concept from literature and field investigation, the research shows the technical and economical virtual simulation advantages in the assembly process. Concluding, we could validate the two propositions: cost reduction with additional assembly equipment related and increase problem solving actions due product and process tooling interferences during design phase.

<p>The unchangeable need of securing and locating parts during different manufacturing processes turned the fixtures to key elements in many part production industries. The iterations between design engineers and manufacturing planners because of late collision detection of the part/fixtures with robots cost a lot of time and money. The lead-time can be reduced by developing tools and/or methods for early verification of the fixtures during the simultaneous engineering phase. Different aspects of fixture designing, modeling and simulating is investigated as a base step to recognize the best practice work to do fixture planning in Process Simulate integrated PLM environment. The aim of the project is to use Process Simulate to design and validate modular fixtures at the same time and in a single environment. It also aims to investigate the possibility of adding kinematics, sensors, and actuating signals to the fixtures and utilize them to model the fixture behavior in a larger simulation study. The project narrows down its focus on the fixtures designed for robotic applications specifically in Automotive Body in White lines without losing generality. The document type stated at the title page and in the header of this page is master thesis work.</p>

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The unchangeable need of securing and locating parts during different manufacturing processes turned the fixtures to key elements in many part production industries. The iterations between design engineers and manufacturing planners because of late collision detection of the part/fixtures with robots cost a lot of time and money. The lead-time can be reduced by developing tools and/or methods for early verification of the fixtures during the simultaneous engineering phase. Different aspects of fixture designing, modeling and simulating is investigated as a base step to recognize the best practice work to do fixture planning in Process Simulate integrated PLM environment. The aim of the project is to use Process Simulate to design and validate modular fixtures at the same time and in a single environment. It also aims to investigate the possibility of adding kinematics, sensors, and actuating signals to the fixtures and utilize them to model the fixture behavior in a larger simulation study. The project narrows down its focus on the fixtures designed for robotic applications specifically in Automotive Body in White lines without losing generality. The document type stated at the title page and in the header of this page is master thesis work.

A manufatura virtual representa uma abordagem emergente que as empresas podem adotar para melhorar seus processos de desenvolvimento de produtos, introduzindo novos produtos no mercado mais rapidamente e a um custo apropriado. A ideia fundamental é criar um ambiente integrado e sintético, composto por um conjunto de ferramentas e sistemas de software, tais como realidade virtual e simulação para apoiar esses processos. O objetivo deste trabalho é analisar a utilização da manufatura virtual no processo de desenvolvimento de produtos em termos de limitações existentes que podem ser superadas, proposta da manufatura virtual, benefícios, e desafios encontrados para sua aplicação. Para a realização da análise, foi desenvolvido um modelo para orientar a aplicação da manufatura virtual no processo de desenvolvimento de produtos que considera: as atividades do desenvolvimento de produtos que podem ser apoiadas por sistemas de software da manufatura virtual; os tipos de sistemas e suas funcionalidades; e alternativas de formatos neutros para habilitar a interoperabilidade de dados. O trabalho foi desenvolvido através da realização de estudos de caso, que forneceram informações para a análise da utilização da manufatura virtual e para a geração do modelo proposto. / Virtual manufacturing represents the emerging approach the enterprises can use to improve their processes, introducing new products more quickly in the market in a cost effective way. The fundamental idea is to create an integrated and synthetic environment, composed of software tools and systems such as virtual reality and simulation to support those processes. The purpose of this work is to analyze the utilization of virtual manufacturing in the product development process regarding current limitations that can be overcome by virtual manufacturing, its proposal, benefits and challenges for its application. For the analysis accomplishment, a product development model in virtual manufacturing environment was developed which considers: the product development activities that can be supported by virtual manufacturing systems; the system types and their functionalities; and neutral formats alternatives to enable data interoperability. The research was done by the accomplishment of case studies that provided information to the impact analysis and to the model development.