For my senior design project in engineering school, we were asked to look at a new factory for a large manufacturer that was having trouble getting product out the door on time. They were completely surprised by the issue since they had directly copied their layout and modus operandi from an existing factory and were at a loss as to what the problem could be.
What AutoCAD didn’t tell them was if you effectively copy and paste the layout of a 100,000 square foot facility into a factory more than double that size, it’s completely normal to have some additional transport time for every single process. While AutoCAD provided a visual representation, it lacked the simulation capabilities necessary to predict and mitigate these logistical challenges. However, there is software existing today that would have prevented that issue from ever taking place.
Simulations Save You Time and Money
NVIDIA has developed OpenUSD-based software called Omniverse that can create highly accurate simulations of our world. This software facilitates precise 3D representation of objects and facilities and—coupled with the ability to replicate operational physics—provides engineers and designers with critical insights into facility performance.
BMW has utilized this software to create a digital twin of their new factory prior to construction, allowing for a solid look at their operation before it begins. This strategy permits the early detection and mitigation of potential process issues stemming from the factory layout, avoiding expensive physical alterations.
This approach also allows them to discern cost-saving measures by simulating both the facility and manufacturing performance in terms of energy use, allowing the designers to make changes to improve energy efficiency up to 35%. Operations can also be streamlined with a focus on cycle time and material flow, guaranteeing a lean operation.
The Best Design and the Best Testing Grounds
Automotive manufacturers are leveraging custom Omniverse-based software to achieve unparalleled vehicle design accuracy. This software can interface with multiple design programs, allowing for real-time collaboration between designers, engineers, and stylists, significantly accelerating the design process. The sophisticated simulation environment allows for rigorous testing, identifying design flaws early, and reducing reliance on physical prototypes. Once the model is complete, the designers can take advantage of the advanced physics in Omniverse to test drive their vehicle and solve any issues that might arise before production begins. Moreover, these simulations provide data that has proven invaluable for training autonomous vehicles, and by replicating complex and hazardous situations in the system, they can ensure the highest level of vehicle safety.
Amazon is using an application built on Omniverse called NVIDIA Isaac Sim to test their new robots in the digital world before deploying them in the real world. By constructing intricate digital twins of their warehouses, Amazon engineers can simulate and refine robotic workflows before utilizing them in the field. Furthermore, this enables them to generate synthetic data that allows for training robots for complex tasks, similar to the automotive industry application for autonomous vehicles. Since this is all digital, robotics can be tested in an extremely wide variety of situations, objectives, and events you might not otherwise be able to test in the physical world, enabling capabilities that wouldn’t be possible with traditional testing. Once trained, these models can be tested before implementation to see how they work in tandem with human workers, minimizing errors and allowing for easier adoption.
From Daunting to Doable
It’s completely understandable to look at the capabilities of this tool and imagine how long and difficult it will be to model every aspect of our physical world. Spending time running simple simulations with preexisting assets on my own was enough to make me think this was simply too big, but then I realized this isn’t meant to be a tool that is used by a single person. It’s a collaborative tool that an entire company with many different roles can use to work together more effectively and save staggering amounts of resources. Digital twins can significantly improve margin and prevent unforeseen issues with large capital investments, so it is certainly a capability worth pursuing for many industries. Naturally, this is an endeavor that is going to be long and arduous. Like any modeling software, it can only be as good as the data that is fed into it.
However, it’s not a challenge you need to tackle alone or even with your team. Connection has endeavored to gain the knowledge and resources to make navigating the Omniverse platform far easier for our customers. If you’re looking into this exciting new technology, don’t hesitate to contact the CNXN Helix Team today. We’re here to ensure that you’ll get the best results as quickly as possible as you delve into new technologies.
To learn more about AI solutions built for manufacturing, visit us our website today.
James Rust
James Rust is an Industry Solutions Specialist at Connection, working to assist with sales and client engagements when communicating the Manufacturing Practice’s value propositions, capabilities, practical use cases, and business outcomes that align with our portfolio of technology solutions. Prior to Connection, James got his start working in a manufacturing shipping department. His career advanced in various industries, including food and beverage, oil and gas supply, machine shop, and pharmaceutical. James offers experience in maintenance management, ERP systems, going paperless, and improving factory floor and office processes.
