<p>This thesis is based on the present needs for the factory planning support, of which the most important ones are:</p><p>• A structured reuse of knowledge and support for industries. Because today the industry handbook in factory planning is not satisfying enough to support this complex process.</p><p>• Better methods to represent and communicate data between software within the factory layout area for easier data communication and thereby information access, exchange and reuse.</p><p>To support the factory planning, based on the mentioned needs, a mapping of the present factory planning process is made based on knowledge from industry and academy. Since the factory planning process is a huge and complex process that no one can handle by themself, a puzzle work is performed. Based on gathered information and knowledge an activity model is developed, to structure the data and information. The model gives a better overview on the actual course of events and in this way also “captures” the most important information to be represented for data exchange among different software applications and different people.</p><p>In this thesis the most important information in factory layout is gathered and structured in a concept model for factory layout. Since the concepts depend on the context in which they are used, it is extremely important to present every concept in its relationship with other related concepts within the area.  A general theory and state-of-the-art definitions in the area is presented and discussed for a factory planning information management system. An evaluation and discussion is made for the state-of-the-art software in the area of concern.</p>

A abertura de mercado no Brasil, na década de 1990, aumentou a concorrência na indústria automobilística local e a busca por novos produtos, tecnologias e principalmente por processos de manufatura mais enxutos e viáveis economicamente. Dentro deste contexto, a pressão pela redução do tempo de desenvolvimento de novos produtos, fez com que fosse necessário reduzir também o tempo de desenvolvimento dos novos processos de manufatura. O desenvolvimento e planejamento de uma manufatura são processos complexos, pois envolvem diferentes áreas da empresa, demanda altos investimentos e envolve diferentes tecnologias. A Engenharia de Manufatura é a área da empresa responsável pelo planejamento, projeto e implantação de novas manufaturas para novos produtos. O objetivo central deste trabalho é a conceituação e aplicação da Simulação de Processos aplicada nas fases de planejamento e projeto para linhas de produção manuais e automatizadas através da utilização de ferramentas computacionais. O foco será na área de armação de carroceria onde se encontram o maior grau de automação e complexidade. As vantagens obtidas com sua utilização, nas fases de planejamento e projeto, são a redução de investimentos, redução no tempo de introdução de um novo processo, observação prematura de gargalos de produção, definição da quantidade necessária de estoques intermediários, os quais influenciam diretamente os tempos de processo e custos variáveis. Os conceitos apresentados são validados a partir de estudos de casos na Volkswagen do Brasil envolvendo veículos em lançamento como o novo Gol e Voyage e veículos em série como o Polo. / The market opening to newcomers in Brazil during the 1990s has increased the local automotive industry competition and the search for new products, technologies and mainly for leaner and financially feasible processes. Within that context, the need to reduce new product development timing has made it necessary to minimize the development period for manufacturing processes. Planning and developing manufacturing operations are complex processes, once they involve different areas in a company and they demand high investment and peculiar technologies. The Manufacturing Engineering is the area in the company that takes over the responsibility for planning, designing and implementing new manufacturing processes for new products. The main objective of that work is define concepts and apply the process simulation on the planning and designing steps of manual and automatic production lines by using computer tools. The target will be the body shop area where the automation and complexity degrees are higher. The advantages of using such tools during the planning and designing phases are not only the reduction of investment and process introduction timing but also the early identification of production bottlenecks, as well as the definition of line buffers that directly affect the process cycles and variable costs. The presented concepts are validated through cases of Volkswagen of Brazil and involving the launching of vehicles such as the new Gol and Voyage and series models like the Polo.

Resumo: A Fábrica Digital é um conceito que melhora a colaboração entre os processos de engenharia, durante o desenvolvimento dos produtos. Suportado por ferramentas de software interligadas por meio de uma base única de dados, este conceito permite que os engenheiros visualizem e corrijam antecipadamente os principais problemas relacionados aos processos de manufatura. Com a simulação tridimensional de uma fábrica virtual é possível determinar, sem a construção de protótipos físicos, como funcionará a fábrica real. A identificação antecipada das modificações de produtos, processos e recursos traz benefícios, uma vez que os custos das revisões aumentam à medida que o produto avança na produção. Mas, apesar dos benefícios trazidos por este conceito, falhas podem ocorrer na sua implantação. Esta pesquisa tem por objetivo apresentar os Fatores Críticos de Sucesso (FCS) na implantação de um projeto de Fábrica Digital em uma empresa Brasileira, usada como estudo de caso. Como pouco se conhece sobre este tipo de projeto, os FCS foram identificados por meio de uma pesquisa exploratória em implantações de sistemas ERP, PLM e sistemas em geral. Após agrupados e validados, foram priorizados utilizando-se os métodos Delphi e AHP, por profissionais de mais três empresas que implantam projetos de Fábrica Digital, no Brasil e exterior. Entre nove FCS identificados, cinco obtiveram as maiores prioridades: apoio e comprometimento contínuo da alta gerência, abrangente reengenharia do negócio, parceiros com conhecimento e experiência, participação e comprometimento do usuário e adequado papel do líder do projeto. As contribuições desta pesquisa são a divulgação da Fábrica Digital, especialmente no Brasil, onde ainda é pouco conhecida e a utilização dos resultados por gerentes de projetos de Fábrica Digital e de projetos similares. / Abstract: The Digital Factory is a concept which improves the collaboration between engineering processes during product development. Supported by software tools interconnected by a single data base, this concept enables engineers to preview the main problems concerning the manufacturing processes, and to correct them in advance. With a three-dimensional virtual factory simulation it is possible to determine how the real factory will work, without the construction of physical prototypes. Prior identification of product modifications, processes and resources can be beneficial due to the increasing revision costs as production processes proceed. Despite the benefits brought by this concept, problems may occur during implementation, though. This research aims at presenting the Critical Success Factors (CSFs) in the implementation of a Digital Factory project in a Brazilian company, used as case study. Because little is known about this kind of project, the CSFs were identified by an exploratory survey on the implementation of ERP and PLM systems as well as on systems in general. After having been grouped and validated, they were given priority through the use of Delphi and AHP methods; this evaluation was carried out by professionals of more three enterprises which implement Digital Factory projects, in Brazil and abroad. Five out of the nine CSFs identified were classified as main priorities: continuous support and commitment of high management, comprehensive business reengineering, skilled and experienced partners, participation and commitment of users, and role properness of the project manager. This research contributions are the Digital Factory divulgence mainly in Brazil, where it is still scarcely known, and the use of those results by managers of Digital Factory projects as well as other similar projects. / Orientador: Maurício César Delamaro / Coorientador: Edgard Dias Batista Júnior / Banca: Marco Antonio Chamon / Banca: Dagoberto Alves de Ameida / Mestre

Made available in DSpace on 2014-06-11T19:29:53Z (GMT). No. of bitstreams: 0 Previous issue date: 2008-09-17Bitstream added on 2014-06-13T21:00:24Z : No. of bitstreams: 1 decarli_pc_me_guara.pdf: 1664662 bytes, checksum: 1be8cac5fe90814456040275f7e3d7f8 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / A Fábrica Digital é um conceito que melhora a colaboração entre os processos de engenharia, durante o desenvolvimento dos produtos. Suportado por ferramentas de software interligadas por meio de uma base única de dados, este conceito permite que os engenheiros visualizem e corrijam antecipadamente os principais problemas relacionados aos processos de manufatura. Com a simulação tridimensional de uma fábrica virtual é possível determinar, sem a construção de protótipos físicos, como funcionará a fábrica real. A identificação antecipada das modificações de produtos, processos e recursos traz benefícios, uma vez que os custos das revisões aumentam à medida que o produto avança na produção. Mas, apesar dos benefícios trazidos por este conceito, falhas podem ocorrer na sua implantação. Esta pesquisa tem por objetivo apresentar os Fatores Críticos de Sucesso (FCS) na implantação de um projeto de Fábrica Digital em uma empresa Brasileira, usada como estudo de caso. Como pouco se conhece sobre este tipo de projeto, os FCS foram identificados por meio de uma pesquisa exploratória em implantações de sistemas ERP, PLM e sistemas em geral. Após agrupados e validados, foram priorizados utilizando-se os métodos Delphi e AHP, por profissionais de mais três empresas que implantam projetos de Fábrica Digital, no Brasil e exterior. Entre nove FCS identificados, cinco obtiveram as maiores prioridades: apoio e comprometimento contínuo da alta gerência, abrangente reengenharia do negócio, parceiros com conhecimento e experiência, participação e comprometimento do usuário e adequado papel do líder do projeto. As contribuições desta pesquisa são a divulgação da Fábrica Digital, especialmente no Brasil, onde ainda é pouco conhecida e a utilização dos resultados por gerentes de projetos de Fábrica Digital e de projetos similares. / The Digital Factory is a concept which improves the collaboration between engineering processes during product development. Supported by software tools interconnected by a single data base, this concept enables engineers to preview the main problems concerning the manufacturing processes, and to correct them in advance. With a three-dimensional virtual factory simulation it is possible to determine how the real factory will work, without the construction of physical prototypes. Prior identification of product modifications, processes and resources can be beneficial due to the increasing revision costs as production processes proceed. Despite the benefits brought by this concept, problems may occur during implementation, though. This research aims at presenting the Critical Success Factors (CSFs) in the implementation of a Digital Factory project in a Brazilian company, used as case study. Because little is known about this kind of project, the CSFs were identified by an exploratory survey on the implementation of ERP and PLM systems as well as on systems in general. After having been grouped and validated, they were given priority through the use of Delphi and AHP methods; this evaluation was carried out by professionals of more three enterprises which implement Digital Factory projects, in Brazil and abroad. Five out of the nine CSFs identified were classified as main priorities: continuous support and commitment of high management, comprehensive business reengineering, skilled and experienced partners, participation and commitment of users, and role properness of the project manager. This research contributions are the Digital Factory divulgence mainly in Brazil, where it is still scarcely known, and the use of those results by managers of Digital Factory projects as well as other similar projects.

A abertura de mercado no Brasil, na década de 1990, aumentou a concorrência na indústria automobilística local e a busca por novos produtos, tecnologias e principalmente por processos de manufatura mais enxutos e viáveis economicamente. Dentro deste contexto, a pressão pela redução do tempo de desenvolvimento de novos produtos, fez com que fosse necessário reduzir também o tempo de desenvolvimento dos novos processos de manufatura. O desenvolvimento e planejamento de uma manufatura são processos complexos, pois envolvem diferentes áreas da empresa, demanda altos investimentos e envolve diferentes tecnologias. A Engenharia de Manufatura é a área da empresa responsável pelo planejamento, projeto e implantação de novas manufaturas para novos produtos. O objetivo central deste trabalho é a conceituação e aplicação da Simulação de Processos aplicada nas fases de planejamento e projeto para linhas de produção manuais e automatizadas através da utilização de ferramentas computacionais. O foco será na área de armação de carroceria onde se encontram o maior grau de automação e complexidade. As vantagens obtidas com sua utilização, nas fases de planejamento e projeto, são a redução de investimentos, redução no tempo de introdução de um novo processo, observação prematura de gargalos de produção, definição da quantidade necessária de estoques intermediários, os quais influenciam diretamente os tempos de processo e custos variáveis. Os conceitos apresentados são validados a partir de estudos de casos na Volkswagen do Brasil envolvendo veículos em lançamento como o novo Gol e Voyage e veículos em série como o Polo. / The market opening to newcomers in Brazil during the 1990s has increased the local automotive industry competition and the search for new products, technologies and mainly for leaner and financially feasible processes. Within that context, the need to reduce new product development timing has made it necessary to minimize the development period for manufacturing processes. Planning and developing manufacturing operations are complex processes, once they involve different areas in a company and they demand high investment and peculiar technologies. The Manufacturing Engineering is the area in the company that takes over the responsibility for planning, designing and implementing new manufacturing processes for new products. The main objective of that work is define concepts and apply the process simulation on the planning and designing steps of manual and automatic production lines by using computer tools. The target will be the body shop area where the automation and complexity degrees are higher. The advantages of using such tools during the planning and designing phases are not only the reduction of investment and process introduction timing but also the early identification of production bottlenecks, as well as the definition of line buffers that directly affect the process cycles and variable costs. The presented concepts are validated through cases of Volkswagen of Brazil and involving the launching of vehicles such as the new Gol and Voyage and series models like the Polo.

Au cours des dernières décennies, le Processus de Développement de nouveaux Produits (PDP) est devenu un processus de plus en plus complexe et itératif, dû à la diversification et la personnalisation des produits et leur complexification. De plus la conception des systèmes de production associés devient une tâche très complexe, sachant que cette phase est liée aux prises de décisions de la stratégie de production qui ont un impact à long terme et qui impliquent un engagement important de ressources financières. Ainsi, les entreprises doivent surmonter ces défis pour concevoir, développer et produire des produits plus rapides et moins chers avec une meilleure qualité. Dans ce contexte, l’Usine Numérique (UN) est une solution basée sur l’emploi de méthodeset outils numériques pour examiner, qualifier et comparer les systèmes de production complexes et ainsi aider la prise de décisions optimales. Cependant, les experts de simulation rencontrent toujours des difficultés lors de prises de décision, dû au manque d’organisation, informations et connaissances. Dans ce travail de recherche, nous nous concentrons sur ce dernier point et proposons un système de gestion des connaissances nommé « KSim » dédié à la gestion de toutes les connaissances pour le développement des projets d’UN et qui supporte la collaboration et la communication entre tous les acteurs de PDP pour faciliter la prise de bonnes décisions dans un temps restreint. / In recent decades, the New Product Development Process (PDP) has become an increasingly complex and iterative process due to the diversification and customization of products and their complexity. Moreover, the design of the associated production systems becomes a very complex task, knowing that this phase is linked to the decision-making of the production strategy which have an impact on long-term and which involve an important commitment of financial resources. Thus, companies must overcome these challenges for design, develop and produce faster and cheaper products with better quality. In this context, the Digital Factory (DF) is a solutionbased on the use of numerical methods and tools to examine, qualify and compare the complex production systems and thus, help to make the optimal decisions. However, the experts of simulation still encounter difficulties in the decision-making due to the lack of organization, information and knowledge. In this research, we focus on this last point and we propose a knowledge management system called "KSim" dedicated to the management of all knowledge for the development of DF projects and which supports the collaboration and communication between all PDP actors to facilitate to make better decisions as soon as possible.

I detta kandidatarbete undersöker jag hur man med hjälp av virtuell verklighet (VR) kan skapa en fabriksmiljö för att bidra till ökad medvetenhet och säkerhetstänk i fabriken.  Undersökningen baseras på en utmaning från Volvo med deras egen fabrik i fokus där dem velat ha en säkerhetsutbildning för deras gångtrafikanter i fabriken. Med hjälp av designperspektivet design thinking har Volvo fått vara delaktiga genom hela processen där vi kunnat skapa en produkt åt dem tillsammans. Undersökningens frågeställning är “Hur kan man med hjälp av Virtual Reality skapa upplevelsen av fabriksmiljö för att bidra till ökad medvetenhet och säkerhetstänk i fabriken?” där jag valt att gestalta detta i ett spel integrerat med VR. Med hjälp av de valda metoderna för designprocessen kunde jag sätta mig in i Volvos problem och skapa en fabrik som efterliknar deras så mycket som möjligt. Volvo själva fick ta del av skapandet genom bilder och videor för att ge feedback om miljön, samt hur realistisk upplevelsen kändes jämfört med deras egen fabrik. För att gestaltningen skulle testas och godkännas av Volvo involverades dem konstant i arbetet. Undersökningen resulterade i ett VR spel med en kort säkerhetsutbildning om fabrikens miljö och vissa faror som kan komma att ske i den. Eftersom ökad medvetenhet och säkerhetstänk hos personer inom arbetet inte kan mätas direkt har frågeställningen kunnat blivit besvarad efter endast ett fåtal test. De personer från Volvo som har testat det gav positiv respons och nya tankar och idéer kring tekniska utbildningar inom säkerhet som dessa har väckts hos många. / In this bachelor thesis I’m examining how to create a factory environment with virtual reality (VR) to contribute to increased awareness and safety mindset in the factory. The examination is based on a challenge from Volvo with their own factory in focus where they wanted to have a safety training for their pedestrians in the factory. With help from the design perspective design thinking, Volvo has been involved through the whole process where we could create a product for them together. The survey question is ”How can you with help from Virtual Reality create the experience of a factory environment to contribute to increased awareness and safety mindset in the factory?” where I chose to shape this into a game integrated with VR. With help from the selected methods for the design process I could put myself into Volvo’s problem and create a factory that resembles theirs as much as possible. Volvo took part of the creation themselves through pictures and videos to provide feedback on the environment and how realistic the experience felt compared to their own factory. For the design to be tested and approved by Volvo, they were constantly involved in the project. The examination resulted in a VR game with a short safety training about the environment of the factory and some dangers that may occur in it. Because increased awareness and safety thinking in people within the work can not be measured directly, the survey question has been answered after only a few tests. The people at Volvo who have tested it gave positive results and new thoughts and ideas about technical training in security, such as these, have been awakened by many.

This thesis is based on the present needs for the factory planning support, of which the most important ones are: • A structured reuse of knowledge and support for industries. Because today the industry handbook in factory planning is not satisfying enough to support this complex process. • Better methods to represent and communicate data between software within the factory layout area for easier data communication and thereby information access, exchange and reuse. To support the factory planning, based on the mentioned needs, a mapping of the present factory planning process is made based on knowledge from industry and academy. Since the factory planning process is a huge and complex process that no one can handle by themself, a puzzle work is performed. Based on gathered information and knowledge an activity model is developed, to structure the data and information. The model gives a better overview on the actual course of events and in this way also “captures” the most important information to be represented for data exchange among different software applications and different people. In this thesis the most important information in factory layout is gathered and structured in a concept model for factory layout. Since the concepts depend on the context in which they are used, it is extremely important to present every concept in its relationship with other related concepts within the area.  A general theory and state-of-the-art definitions in the area is presented and discussed for a factory planning information management system. An evaluation and discussion is made for the state-of-the-art software in the area of concern.

Final thesis is focused on design of experimental workplace with industrial robots for manipulation operations, that will be used for educational and demonstrational purposes. Integration of sub-systems and workplace layout are worked out in this thesis. Key factor is so called virtual commissioning. Unique solution, which is contained within final thesis, combines several software tools for the design of robotic workplace. Static 3D model created in Autodesk Inventor Professional is imported into Tecnomatix Process Simulate, where dynamic 3D model is made – simulation model respectively. The control element is softPLC by Beckhoff company created in TwinCAT software. The connection of simulation model and control element is realized using standardized communication protocol OPC UA. This combination proved to be a cheap tool for virtual commissioning in practice, because only one personal computer is needed for the job.

I detta kandidatarbete undersöker vi hur med hjälp av virtuell verklighet (VR) kan gestalta en fabriksmiljö och upplevelse som ökar säkerhetstänket för nyanställda på Volvo i Olofström. Undersökningen utgår ifrån vårt samarbete med Volvo och deras egen fabrik som är i fokus där de har velat ha en säkerhetsutbildning inom VR för deras nyanställda och gångtrafikanter i fabriken. Med hjälp av designperspektivet digital didaktisk design har vi kunnat ställa i centrum på lärandet i görandet, att planera och skapa aktiviteter för någon så att användaren i fråga kan tillägna sig nya kunskaper. Frågeställningen inom denna undersökning är “Hur kan man skapa en fabriksmiljö inom VR som främjar lärande.” Med hjälp av metoderna vi valde för designprocessen kunde vi gestalta en fabrik som simulerar deras och även främja lärandet för säkerhetstänket som var en viktig del att komma till insikt om. Resultatet på undersökningen är att vi skapade en VR-prototyp med hjälp utav spelmotorn Unity. I denna VR-prototyp tar användaren igenom sig en livlig och hektisk fabriksmiljö som speglar det vi själva har fått uppleva genom våra observationer när vi var på besök hos Volvo i Olofström. Genom våra undersökningar inom VR säkerhet har vi upphöjt vår förståelse om vilka möjligheter VR har inom lärandet och att förmedla information. Dem viktiga punkterna för oss var att öka säkerhetstänket hos användaren genom att placera dem i scenarion där deverkligen får uppleva hur det verkligen är att vara inom en livlig fabrik och vad som förväntas av dem. Nyckelord: Virtuell verklighet (VR), säkerhetsträning, fabriksmiljö, Volvo / In this bachelor thesis, we investigate how, with the help of virtual reality (VR), we can create a factory environment and experience that increases the safety thinking for new employees at Volvo in Olofström. The survey is based on our collaboration with Volvo and their own factory, which is in focus where they have wanted a safety training in VR for their new employees and pedestrians in the factory. With the help of the design perspective digital didactic design, we have been able to put the focus on learning in practice, to plan and create activities for someone so that the user in question can acquire new knowledge. The question in this study is "How to create a factory environment within VR that promotes learning." With the help of the methods we chose for the design process, we were able to design a factory that simulates theirs and also promote learning for safety thinking, which was an important part to gain insight into.  The result of our research is that we have created a prototype with the help of the game engine Unity through this process that takes the user through a lively and hectic factory environment that reflects what we ourselves have experienced through our observations when we visited Volvo in Olofström. Through our research in VR security, we have raised our understanding of what opportunities VR has in learning and to convey information. The important points for us were to increase the security thinking of the user by placing them in scenarios where they really get to experience what it really is like to be in a lively factory and what is expected of them Keywords: Virtual reality (VR), safety training, factory environment, Volvo