Using 3D to deliver a new view of manufacturing

Chrysler expands use of technology to help deliver products faster, better.

08/07/2012


Chrysler Group LLC is using the world of 3D to change the way it looks at planning for future products and implements World Class Manufacturing (WCM) before a single machine is built or installed.

During a speech at the Management Briefing Seminars in Traverse City, Mich., on Aug. 6, 2012, Chrysler Group vice president Brian Harlow said that the company has brought 3D into its upfront processes in order to prepare for the launch of two important new transmissions in Kokomo, Ind., – the eight-speed rear-wheel drive and nine-speed front-wheel drive – as well as other new powertrain programs.

"We knew we needed a new way of working in order to get our plants in Kokomo ready at an accelerated pace," said Harlow. "By using 3D technology, we are in effect injecting the principles of WCM from the very beginning of our planning for production startups such as the ones in Kokomo."

The goal of WCM is to continuously improve performance in order to reach the objective of zero waste, which includes zero accidents, zero breakdowns, zero waste of motion and zero inventories.

Chrysler Group is utilizing a three-dimensional modeling system specifically for powertrain manufacturing to help everyone see the shop floor as it really is and not how one might imagine it is.

"We live in three dimensions, not two, so with a two dimensional drawing, you had to imagine the third dimension," said Harlow. "Engineers have good imaginations, but those imaginations don't all work the same way. If you have 10 engineers looking at a 2D drawing, they will all see it a little differently."

By turning the view, Harlow said that engineers can see the manufacturing environment, including equipment, materials and operators, as it really is. In this way, issues that may delay a program or cost money to fix are addressed even before the first piece of equipment arrives at the plant.

"Three-dimensional modeling allows us to make our actual investments as late as possible in the launch process," said Harlow. "The goal is to make the launch process as vertical as possible because this shortens the time it takes to recover our investment."

The software also has the capability of showing an exploded view of a machine. By de-contenting the machine, an operator can see all of the nuts and bolts, making it easier to understand how it goes together, maintain and repair.

"Animation is another critical aspect of the 3D programming," said Harlow. "It allows us to validate cycle times and to discover system-related issues even before the machinery is made.

"If there is a situation anywhere that compromises production, we can identify it up front in the process, something we ordinarily wouldn't know until the first day of production," continued Harlow. "Now we can be proactive. We can change cycle times by moving content or by making changes with the machine tool builder."



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2017 Top Plant.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
March 2018
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
December 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Maintenance & Safety
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
Industrial Analytics
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
IIoT: Operations & IT
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me