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BMW has standardized on a new technology 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 achieved this all the way down to work order directions for manufacturing unit staff from 31 factories in its manufacturing community, lowering manufacturing planning time by 30%, the corporate stated.
Throughout Nvidia’s GTC November 2021 Conference, members of BMW’s Digital Options for Manufacturing Planning and Information Administration for Digital Factories supplied an replace on how far BMW and Nvidia have progressed in simulating manufacturing operations counting on digital twins. Their presentation, BMW and Omniverse in Production, gives 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 primarily based on constraints all the way down to work order directions and robotics programming on the store ground.
Bettering product high quality, lowering manufacturing prices and unplanned downtime whereas growing output, and guaranteeing employee security are objectives all producers try for, but seldom attain persistently. Reaching these objectives has way more to do with how fluid and real-time the information from manufacturing and course of monitoring, product definition, and store ground scheduling is shared throughout manufacturing in a understandable format every staff can use.
Overcoming the challenges of reaching 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 information manufacturing operations generate every day. Getting probably the most worth out of information that any given manufacturing operation generates every day is the essence of good manufacturing.
Defining What A Manufacturing unit of the Future Is
McKinsey and the World Financial Discussion board (WEF) are learning what units distinctive factories other than all of the others. Their preliminary collaborative analysis and lots of subsequent research studies, 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 right now. As well as, McKinsey and WEF have set excessive requirements of their definition of what a manufacturing unit of the longer term 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 know-how platforms, robust efficiency on change administration, and adaptableness to altering provide chain, market, and buyer constraints, whereas sustaining visibility and price 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 gives a geographical view of lighthouse producers’ manufacturing unit areas globally.
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 longer term. Core to their blueprint is getting back-end integration companies proper, together with real-time integration with ProjectWise, BMW inner methods Prisma and MAPP, and Tecnomatix eMS. BMW depends on Omniverse Connectors that assist dwell 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 varied back-end and front-end methods at scale so their tech stack might 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 longer term initiatives whereas others fail. BMW acknowledged early that every system’s completely 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 information everybody might perceive. Nvidia Omniverse acts as the information orchestrator and gives data each division can interpret and act on. “International groups can collaborate utilizing completely 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 shortly configured to provide any certainly one of ten completely different automobiles, every with as much as 100 choices or extra throughout ten fashions, giving customers up to 2,100 ways to configure a BMW. As well as, Nvidia Omniverse offers BMW the flexibleness to reconfigure its factories shortly 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. In consequence, each step in customizing a given mannequin displays buyer necessities and likewise be shared in real-time with every manufacturing staff. 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 shortly 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 right now. Combining real-time manufacturing and course of monitoring knowledge with simulated outcomes helps BMW’s engineers shortly determine areas for enchancment, so high quality, value, and manufacturing effectivity objectives preserve getting achieved.
For any producer to succeed with a fancy product customization technique like BMW has, all of the methods that manufacturing depends on should be in sync with one another in real-time. There must be a typical cadence the methods are working at, offering real-time knowledge and data every staff can use to do their particular jobs. BMW is reaching this right now, enabling them to plan all the way down to the model-by-model configuration degree at scale. They’re additionally in a position to take a look at every mannequin configuration in a completely functioning digital twin setting 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 switch digital twins to utterly take a look at any new enchancment earlier than making it dwell in manufacturing.
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