IIoT-enabled Polylemma of Production System for Composite Intensive Vehicle Manufacturing.

Paper #:
  • 2017-01-0290

Published:
  • 2017-03-28
Abstract:
The advancements in automation, big data computing and high bandwidth networking has expedited the realization of Industrial Internet of Things (IIoT). IIoT has made inroads into many sectors including automotive, semiconductors, electronics, etc. Particularly, it has created numerous opportunities in the automotive manufacturing sector to realize the new aura of platform concepts such as smart polylemma of production technologies. The stringent CAFE standards set forth by the Obama administration has pushed the automotive industry to radically revolutionize and design lightweight systems using advanced materials such as composites. Despite several outstanding benefits, advanced materials often come with additional costs. Minimizing physical infrastructure and improving efficiency will make the use of these materials affordable. This paper provides a thought provoking application of IIoT in automotive composites body shop. By creating a digital twin for every physical part, we no longer need to adhere to the conventional manufacturing processes and layouts, thus opening up new opportunities in terms of equipment and space utilization. The century-old philosophy of the assembly line might not be the best layout for vehicle manufacturing, thus proposing a novel assembly grid layout inspired from a colony of ants working to accomplish a common goal. Costs per part are compared between the traditional and proposed manufacturing processes/layout using virtual plant simulation tools. Moreover, the study proposes real-time multilayer communication that vastly improves tasks such as inventory management, proactive/preventive maintenance, inline quality control, flexibility to part variabilities and design development. Finally, improvements in space, energy and manpower utilization are also clearly addressed thus providing a viable business case and insight for what the future of automotive manufacturing could be.
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