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Manufacturing Simulation for Industrial Projects

Abstract

Manufacturing simulation is a major component of the technology program at our university, and has provided opportunities for numerous industrial projects. This software application is being used extensively by many major corporations to model, analyze, and optimize complex manufacturing operations, including Boeing, Lockheed-Martin, Daimler-Chrysler and Toyota. Companies are utilizing these advanced 3D digital manufacturing tools as a component of their product life-cycle management to optimize and continuously improve the manufacturing processes. In many cases simulations are mandatory prior to implementation of any significant new operation, project or process. Manufacturing technologists and engineers need to be familiar with these modern tools and their applications, and to understand when and how to effectively utilize them. At our university these applications are being taught under the title of virtual simulation (VS). This paper explains how VS has been integrated into our curriculum, and has been used to establish effective partnerships with major manufacturing companies.

Introduction

We are in our eighth year of a curriculum utilizing advanced industrial computer simulation software. The virtual simulation classes are offered in a sequence of three quarters, earning four credits per quarter. Students learn specific simulation applications from tutorials and online course materials. Teams of students then work with local companies to create simulation models of actual manufacturing operations. Each student team prepares PowerPoint materials which are presented to representatives of the company. Recent projects included work with major automotive original equipment manufacturers (OEMs) and suppliers, along with a major defense industry company. This paper and presentation includes examples of simulations and the results of the students’ analysis of the operations.

The simulation applications used in these industrial projects include robotic workcell processing, ergonomics analysis, and discrete event materials/process flow studies. This curriculum has also provided an opportunity for integration of several technologies and manufacturing management aspects into application-based environments, including 3-D CAD modelling, robotics, and production system design. Students gain skills and experience in teamwork, project planning, problem solving, and formal multi-media presentations in industrial environments. Benefits include exposure to in-plant manufacturing operations, and the opportunity to personally deal with company professionals. Current students have obtained coop/internship positions, and graduates are finding simulation jobs in the fields of manufacturing and applications engineering.

Program Background

A grant from the Society of Manufacturing Engineers in 1997 permitted the initial offering of virtual simulation (VS) as a senior capstone project for technology majors. By the summer of 1999, simulation internships had placed 12 of 17 students after running full-scale simulation

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Nutter, P. (2006, June), Manufacturing Simulation For Industrial Projects Paper presented at 2006 Annual Conference & Exposition, Chicago, Illinois. 10.18260/1-2--1214