Digital Manufacturing Turning 3D manufacturing solutions into real productivity gains

SHOP-FLOOR SIMULATION REAL-WORLD PRODUCTIVITY

Automotive and aerospace companies across the globe collaborate with the Tata Technologies digital manufacturing team to infuse their manufacturing operations with intelligent project preparation and resource optimization.

Who is the client?

Tier 1 aerospace and automotive manufacturers around the world rely on Tata Technologies for end-to-end digital manufacturing services. Our global roster of well-known digital manufacturing clients includes Tata Motors, Airbus, Nissan, Durr and General Motors. The Tata Technologies digital manufacturing team applies a pragmatic approach to each clients business challenge and finds an effective solution using a blend of cutting-edge technology and real-world experience. By optimizing the clients plant layout, processes, robotics and human ergonomics, Tata Technologies helps companies achieve maximum operational efficiency and reduce manufacturing costs.

What was the challenge

Digital manufacturing specialists from Tata Technologies have worked with companies of various sizes and complexities to achieve better manufacturing. Our numerous project challenges include: Optimizing a Wing Manufacturing Facility A major aerospace manufacturer wanted to build a second wing manufacturing plant in the U.K. The company needed to: Analyze the assembly line, storage space, factory layout and material handling system Evaluate and reduce the number of trips made by the companys planes between the existing and planned facilities Upgrading a Major Automakers Plant A large automotive manufacturer needed

to assess the feasibility of producing a new vehicle model using its existing facilities and resources. The client wanted in-depth analysis of: Plant layout Human ergonomics Robotics line Manufacturing processes Material flow

Maximizing an Automotive OEMs Assembly Line The client wanted a digital manufacturing solution to improve the efficiency of its assembly line. Key challenges of the project included: Factory flow simulation Process planning Auto line balancing Station validation Logistics planning

What was the solution?

Tata Technologies met the challenges outlined above with the following solutions: Optimizing a Wing Manufacturing Facility The digital manufacturing team collaborated with the client to study and develop the layout of complex equipment and process configurations. The two teams worked together to: Optimize the plant layout for better floor space utilization Develop an a safe and ergonomically sound material handling system Streamline processes to improve cycle time, loading time, unloading time, setup time and batch sizes Upgrading a Major Automakers Plant Tata Technologies used DELMIA to virtually simulate the clients plant layout, robotics and human resources. The digital 3D model enabled Tata Technologies and the client to: Optimize and validate plant layout and storage space Simulate and streamline material flow along the trim, chassis and final line Simulate and optimize the clients existing robotic line Dynamically simulate the cockpit fitment process to improve human ergonomics Maximizing an Automotive OEMs Assembly Line Tata Technologies and the client developed critical assembly line planning solutions using DELMIA. The resulting solutions included:

Creating benchmarks for the new shop for the number of stops and the number of operators Validating processes to determine that design changes to tooling and equipment were not necessary Exploring various domain, software and logistics planning requirements for current and future utilization

Why Tata Technologies?

What are the short term benefits?

Tata Technologies deploys the largest workforce in India focused solely on providing complete solutions in the digital manufacturing domain from planning to layout to simulation to implementation. Our digital manufacturing solutions enable engineers to make intelligent decisions in the virtual environment without committing to the costs of physical equipment. The Tata Technologies digital manufacturing team has more than 97,000 hours of combined experience in throughput simulation, robotic simulation, assembly simulation and process planning.

The Tata Technologies digital manufacturing team works with clients to intelligently plan the manufacturing process and predict and resolve issues before production begins. Short-term benefits include: Advanced virtual simulation using DELMIA Improved production plans for space and resource utilization Improved production speed due to better planning and processes Streamlined material flow Optimized robotics for reduced idle time, shortened cycle time and smoother robot motion Enhanced human ergonomics

Find out more

For more information about the digital manufacturing capabilities at Tata Technologies, visit our website at www. tatatechnologies. To learn more about our automotive and aerospace solutions, please contact us at: betterauto@tatatechnologies.com or betteraero@tatatechnologies.com.

What are the long term benefits?

Our automotive and aerospace clients kick off new manufacturing projects with the knowledge that their processes, technology and facilities are configured for optimal performance. Tata Technologies makes it easier for clients to evolve their operations to meet future project requirements with an integrated blend of digital modeling, process planning and end-toend solution implementation.

 Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.