KICKOFF MEETING LEONARDO DA VINCI PROJECT TAMPERE, 09-10/11/2006 Contribution from IRCCyN Ecole Centrale de Nantes Alain BERNARD Professor at Ecole Centrale Nantes Deputy Director for Research «Virtual Engineering for Industrial Engineering» research team of IRCCyN (Research Institute for Communication and Cybernetics of Nantes) Alain.bernard@irccyn.ec-nantes.fr 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 1
Key elements of the sector in France The mechanical sector is characterised by entreprises from three main industrial branches: - mechanical equipments: machines, energy equipments - industrial services for metal work or mechanical subcontracting - metallic products manufacturing 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 2
Key elements of the sector in France - a structured domain, linked to industry by customer/provider relationship - a proportion of qualified jobs higher than the one of production industry - the increasing proportion of large international group financing - innovation: integrators, architects 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 3
Key elements of the sector in France The mechanical sector has to face new challenges due to: - worlwide markets and business - the development of «extended entreprises», with a transfert of the responsabilities between customer and provider: no more «capacity subcontracting», increase of standards fo safety, health, environment - more and more requirements that impact quality, delivery time, reliability, safety - decrease of time to market and customisation of products - difficulty for attracting employees (less attractivity for young people) - the skills for mold manufacturing are in mechanics and casting 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 4
Key elements of the sector in France - mold and pattermaking manufacturing is a subcontracting activity for many sectors - mold manufacturers contribute actively to industrial toolings related to specific fabrications (rubber, plastics, glass, metal) 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 5
Key elements of the sector in France - after designer definition: model manufacturing (resin, wood, plastics,metal) - fabrication of models using traditionnal technics (machining, assembly) or rapid prototyping - use of a wide scope of competencies technologies (polishing to HSM) - necessity and benefit of working with partners sometimes not close to the company - creation of shared manufacturing units - co-design with the customer for delivery time reduction and quality increase 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 6
Key elements of the sector in France - mold, model and pattern making is a sector with companies that have less than 500 employees (SMEs), and most of them have less than 50 employees REPARTITION OF THE MARKET SECTORS Molds for rubber and plastics Molds for glass and Mineral materials Models Molds for metallic and stainless metals 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 7
MAIN INTERNATIONAL ECONOMIC PARTNERS In France: 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 8
Necessity of an evolution Definition of alliance strategies Development of core competencies Development of business on new markets Integration of new technologies Better use of numerical integration Better use of «virtual-physical» interaction 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 9
Necessity of an evolution In France: 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 10
In France: 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 11
QUESTIONS Alain.Bernard@irccyn.ec-nantes.fr 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 12
Experience A NUMERICAL ENGINEERING APPROACH FOR VIRTUAL MANUFACTURING AN APPLICATION: SAND CASTING 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 13
Main phases of Sand casting Life-cycle Positioning Development 2D Drawings Production Parts delivered to the client 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 14
Positioning phase Conditional and variational costing application Fully based on the company processes 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 15
Positioning phase Conditional and variational costing application Fully based on the cost inductors related to the processes 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 16
Development phase Sand casting part modelling Modelisation of 2D drawings Integration of draft angles and machining excess material 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 17
Development phase Mechanical properties study Constraints study Deformations study Design and analysis tools integrated in the CAD environment Study integrated into the product development methodology 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 18
Synthesis of the key elements Prototypes Machining Models Machining 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 19
Improvements for the development phase Process modelling specific menus Dialog boxes KBE tools development process-oriented and integrated into the same development environment 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 20
Improvements for the development phase Process modelling Interface with the conditional et variational costing application 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 21
Improvements for the development phase Process modelling Creation of the clusters Modeling of the feeling system 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 22
Improvements for the development phase Process modelling Definition of the CAD architecture Automatic management of the different configurations Creation topological numerical reference system 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 23
Improvements for the development phase Simulation Material feeling simulation Solidification simulation 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 24
Improvements for the development phase Rapid tooling Génération de parcours d'usinage Application of standard manufacturing strategies 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 25
Improvements for the development phase Development of a specific assembly methodology of patterns integrated into the design process of parts and tools Rapid tooling Feature recognition and automatic generation of machining processes Drilling of positioning holes of the models Drilling of holes for the positioning and the fixation of raw material blocs the positioning and the fixation of models 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 26
Improvements for the development phase Economical tooling User-friendly software Definition of standard processes Reduced cost = minimum exploitation cost 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 27
Improvements for the development phase Economical tooling Model Patterns Machining in overlaping time = minimum exploitation cost 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 28
Improvements for the development phase Rapid tooling Correspondance between the manufactured patterns and their numerical model Improvement of the simulation results 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 29
Synthesis of the key elements Part patterns Machining Models Tools patterns Machining Plates Machining 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 30
Improvements for the development phase Conclusions Reduction by 50% of costs and of 60% of development time Realisation of prototypes in the same time than the commercial offer Improvement of the dimensionnal quality of tools and parts Optimization of parts geometry for given mechanical properties Optimization of manufacturing processes 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 31
Separation Improvements for production Separation and finishing Finishing 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 32
Improvements for production Separation and finishing Excess of material Deformations Important mix-product and small batch production 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 33
Improvements for production from tooling to final parts Patterns Molds manufacturing Molds Casting process Clusters and parts Separation and finishing 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 34
Reference model Improvements for production control and validation of tools Control Indicators Validation of tools by vision measuring 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 35
Improvements for production control and validation of molds Reference model Control Indicators Validation of molds Identification of material excess risk 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 36
Improvements for production atomatisation of separation phase Reference model Control Indicators Localisation of parts in space Validation of parts 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 37
Improvements for production atomatisation of separation phase Development of prototype cell 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 38
Improvements for production conclusions Automatisation of separation phase Reduction by 60% of man power of separation and finishing phases Reduction of the scrap ratio 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 39
Global synthesis Increase of the production capacity Control of the impact of technical parameter choice on the economical results Reduction of development cost and time Control of production capabilities and scheduling Improvement of quality ratios Product/Process 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 40
Global synthesis Demand Positioning Requirements Commercial offer NO Client OK YES Order for prototypes Numerical reference model Development Prototype parts Information flow Material flow Not OK Reception OK Manufacturing orders Production Numerical reference model Parts Indicators 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 41
QUESTIONS Alain.Bernard@irccyn.ec-nantes.fr 09-10/11/2006 Kickoff meeting - Leonardo Da Vinci project - Tampere - Prof. A. BERNARD 42