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BMW has standardized on a brand new expertise unveiled by Nvidia, the Omniverse, to simulate each side of its manufacturing operations, in an effort to push the envelope on good manufacturing.
BMW has executed this right down to work order directions for manufacturing unit employees from 31 factories in its manufacturing community, lowering manufacturing planning time by 30%, the corporate stated.
Throughout Nvidia’s GTC November 2021 Convention, members of BMW’s Digital Options for Manufacturing Planning and Knowledge Administration for Digital Factories offered an replace on how far BMW and Nvidia have progressed in simulating manufacturing operations counting on digital twins. Their presentation, BMW and Omniverse in Manufacturing, supplies an in depth tour of how the Regensburg manufacturing unit has a completely functioning, real-time digital twin able to simulating at scale manufacturing and finite scheduling based mostly on constraints right down to work order directions and robotics programming on the store flooring.
Enhancing product high quality, lowering manufacturing prices and unplanned downtime whereas growing output, and making certain employee security are objectives all producers try for, but seldom attain persistently. Reaching these objectives has far more to do with how fluid and real-time the information from manufacturing and course of monitoring, product definition, and store flooring scheduling is shared throughout manufacturing in a understandable format every workforce can use.
Overcoming the challenges of attaining these objectives motivates producers to undertake analytics, AI, and digital twin applied sciences. On the coronary heart of those challenges is the necessity to precisely decipher the large quantity of knowledge manufacturing operations generate day by day. Getting essentially the most worth out of knowledge that any given manufacturing operation generates day by day is the essence of good manufacturing.
Defining What A Manufacturing facility of the Future Is
McKinsey and the World Financial Discussion board (WEF) are finding out what units distinctive factories aside from all of the others. Their preliminary collaborative analysis and lots of subsequent analysis research, together with the creation of the Shaping the Way forward for Superior Manufacturing and Manufacturing Platform, mirror how productive the collaborative efforts of McKinsey and the WEF are at this time. As well as, McKinsey and WEF have set excessive requirements of their definition of what a manufacturing unit of the long run is, as they’re offering ongoing evaluation of the choose group of producers’ operations for purchasers.
Based on McKinsey and WEF, lighthouse producers scale pilots into built-in manufacturing at scale. They’re additionally identified for his or her scalable expertise platforms, sturdy efficiency on change administration, and flexibility to altering provide chain, market, and buyer constraints, whereas sustaining visibility and value management throughout the manufacturing course of. BMW Automotive is an inaugural member of the lighthouse manufacturing corporations McKinsey and WEF first recognized after evaluating over 1,000 corporations. The next graphic from McKinsey and WEF’s analysis supplies a geographical view of lighthouse producers’ manufacturing unit areas globally.
Above: McKinsey and WEF’s ongoing collaboration supplies new insights into how producers can proceed to undertake new applied sciences to enhance operations, add better visibility and management throughout store flooring, and maintain prices in test. Supply: McKinsey and Firm, ‘Lighthouse’ producers prepared the ground—can the remainder of the world sustain?
BMW’s Factories of the Future Blueprint
The 4 classes BMW contributed to throughout Nvidia’s GTC November 2021 Convention collectively present a blueprint of how BMW transforms its manufacturing facilities into factories of the long run. Core to their blueprint is getting back-end integration providers proper, together with real-time integration with ProjectWise, BMW inside methods Prisma and MAPP, and Tecnomatix eMS. BMW depends on Omniverse Connectors that assist reside sync with every utility on the entrance finish of their tech stacks. Entrance-end purposes embody many main 2D and 3D computer-aided design (CAD), real-time visualization, product lifecycle administration (PLM), and superior imaging instruments. BMW standardized on Nvidia Omniverse because the centralized platform to combine the assorted back-end and front-end methods at scale so their tech stack may scale and assist analytics, AI, and digital twin simulations throughout 31 manufacturing vegetation.
Excel at customizing fashions in real-time
How BMW deployed Nvidia Omniverse explains why they’re succeeding with their manufacturing unit of the long run initiatives whereas others fail. BMW acknowledged early that every system’s totally different clock speeds or cadences integral to manufacturing, from CAD and PLM to ERP, MES, High quality Administration, and CRM, wanted to be synchronized round a single supply of knowledge everybody may perceive. Nvidia Omniverse acts as the information orchestrator and supplies data each division can interpret and act on. “International groups can collaborate utilizing totally different software program packages to design and plan the manufacturing unit in real-time, utilizing the potential to function in an ideal simulation, which revolutionizes BMWs planning processes,” says Milan Nedeljković, member of the Board of Administration of BMW AG.
Product customizations dominate BMW’s product gross sales and manufacturing. They’re at the moment producing 2.5 million autos per 12 months, and 99% of them are customized. BMW says that every manufacturing line may be rapidly configured to provide any one in every of ten totally different automobiles, every with as much as 100 choices or extra throughout ten fashions, giving clients as much as 2,100 methods to configure a BMW. As well as, Nvidia Omniverse offers BMW the flexibleness to reconfigure its factories rapidly to accommodate new large mannequin launches.
Simulating line enhancements to save lots of time
BMW succeeds with its product customization technique as a result of every system important to manufacturing is synchronized on the Nvidia Omniverse platform. Consequently, each step in customizing a given mannequin displays buyer necessities and in addition be shared in real-time with every manufacturing workforce. As well as, BMW says real-time manufacturing monitoring knowledge is used for benchmarking digital twin efficiency. With the digital twins of a whole manufacturing unit, BMW engineers can rapidly determine the place and the way every particular fashions’ manufacturing sequence may be improved. An instance is how BMW makes use of digital people and simulation to check new workflows for employee ergonomics and effectivity, coaching digital people with knowledge from actual associates. They’re additionally doing the identical with the robotics they’ve in place throughout plant flooring at this time. Combining real-time manufacturing and course of monitoring knowledge with simulated outcomes helps BMW’s engineers rapidly determine areas for enchancment, so high quality, value, and manufacturing effectivity objectives maintain getting achieved.
Above: BMW simulates robotics enhancements utilizing Nvidia’s Omniverse first earlier than introducing them into manufacturing runs to make sure better accuracy, product high quality, and value objectives are going to be met.
For any producer to succeed with a fancy product customization technique like BMW has, all of the methods that manufacturing depends on have to be in sync with one another in real-time. There must be a standard cadence the methods are working at, offering real-time knowledge and knowledge every workforce can use to do their particular jobs. BMW is attaining this at this time, enabling them to plan right down to the model-by-model configuration degree at scale. They’re additionally in a position to check every mannequin configuration in a completely functioning digital twin surroundings in Nvidia’s Omniverse, after which reconfigure manufacturing traces to provide the brand new fashions. Actual-time manufacturing and course of monitoring knowledge from present manufacturing traces and digital twins assist BMW’s engineering, and manufacturing planning groups know the place, how, and why to change digital twins to utterly check any new enchancment earlier than making it reside in manufacturing.VentureBeat
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