Ford introducing virtual factory to improve efficiency

Ford introducing virtual factory to improve efficiency

In a move to cut costs and improve efficiency, Ford is developing a complete virtual factory to simulate assembly line production processes. This will enable engineers to work together on ‘virtual build events’ and conduct 3D vehicle analysis without actually having to go to the real factory.

Ford was actually the first to simulate vehicle assembly on computers for facilities worldwide in 1997. Now it will use sophisticated camera equipment, including special projectors and polarising motion-sensing glasses to digitise its real-world manufacturing processes, with its Valencia plant in Spain the first to receive this technology. In future, evaluations and analyses of Ford plants around the globe can be conducted remotely from there.

“We can piece together complete cars in a virtual environment and assess the construction down to the finest detail,” says Ford of Germany’s implementation manager Nick Newman.

Ford introducing virtual factory to improve efficiency

Even the actions of assembly line workers (male and female) in the real world can be simulated in order to ergonomically avoid strenuous postures and positions during the operation of machinery, down to the movement of fingers within an enclosed space. Ford says their virtual employee ‘Jack’ can uncover 80 per cent of ergonomic issues at simulation stage.

The company is also increasingly using ‘augmented reality’ vehicles. Data is collected on every single component and the car can be ‘built’ from start to end in a virtual environment.

In Cologne, Germany, Ford’s Cave Automatic Virtual Environment (CAVE) facility can evaluate aspects like visibility, instrument reach, ergonomics and roominess before a prototype is built.

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Jonathan James Tan

While most dream of the future, Jonathan Tan dreams of the past, although he's never been there. Fantasises much too often about cruising down Treacher Road (Jalan Sultan Ismail) in a Triumph Stag that actually works, and hopes this stint here will snap him back to present reality.

 

Comments

  • Visitor on Aug 02, 2012 at 11:26 am

    Boeing 777 aircraft was ‘assembled’ this way…just for info only…:)

    Like or Dislike: Thumb up 0 Thumb down 0
  • Aso desuka…
    Usually, automotive technology will follow suit of aerospace and F1 technologies.

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  • weechan on Aug 02, 2012 at 5:34 pm

    Haha….nice one. I’m actually the authorized reseller of this Siemens Tecnomatix Jack software! But too bad non of the companies in Malaysia have thought to implement Virtual Ergonomic design at this moment.
    There are only couple of local universities trying to do research using Jack Human Simulation software.

    Like or Dislike: Thumb up 0 Thumb down 0
  • Gavin on Aug 02, 2012 at 9:12 pm

    Strange their cars aren’t better, the focus earn title as most suitable for elderly because it’s the most ergonomic car

    Like or Dislike: Thumb up 0 Thumb down 0
 

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