A Virtual Factory Model for Learning and Teaching of Product and Process Design

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A Virtual Factory Model for Learning and Teaching
of Product and Process Design

• Albert C K Choi
• Department of Industrial and Systems Engineering

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Aim of the Project

• This project aims at
• using virtual manufacturing applications in the
  subject area of product design and manufacture
• It is proposed to develop teaching and learning
  materials with integrated case study using
  multi-media format for illustrating various
  methods and computer tools in product design and
  process analysis
• Problem based learning activities would be
  incorporated into the various stages of the
  project

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The Digital (Virtual) Factory

• A newly established laboratory with world class
  software and hardware facilities
• To provide an interactive graphical-based
  discrete event simulation environment for
  students researchers to model develop
  experiment analyze and optimize design and
  manufacturing processes in a digital (virtual)
  environment prior to production

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New Curriculum Under Development

• Alongside with the development of the Digital
  Factory in the Department a framework of a new 9
  credit student centered learning activity titled
  Integrated Product and Process Design (IPPD)
  has been developed.
• The activity based on the Virtual Factory
  concept.
• This is to be implemented in the final year of
  the BEng/MEng course in Industrial and Systems
  Engineering.

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Objective

• This subject is aimed to integrate the different
  aspects in the area of product and process design
  through an integrated problem base learning
  approach.
• The learning activities are carried out in the
  Digital Factory laboratory which provides a self
  learning interactive flexible and graphic-based
  digital simulation environment for students to
  model develop experiment analyze and optimize
  product design and manufacturing process
  including plant layout.

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Teaching and Learning Approach

• The subject is conducted with problem based
  approach.
• The student group has to determine the knowledge
  they need to master in order to complete the task
  requirements.
• The knowledge is arranged as a range of study
  modules which are available to the students for
  choosing.
• These modules are designed with student-centered
  nature with coverage of differing virtual design
  and manufacturing tools.
• A mixture of lectures briefings seminars
  tutorials simulation exercises and case studies
  will be used to deliver the various topics so
  that students are able to complete the task
  activities.
• At the end each student is required to compile an
  overall portfolio to illustrate the learning
  outcomes.

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Framework
IPPD Task Activities
Virtual Manufacturing Learning Modules
Product Design
Process Design and Optimization
Plant Workplace Design
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Typical Student Centered Study Modules  

• Computer Aided Design using Pro-E UG Solid
  Work and Catia
• Product Data Management SmarTeam
• e-Manufacturing using eM Power and QUEST
• Virtual Machining using IGRIP VNC
• Virtual Assembly using Dynamo
• Design for Assembly using Boothroyd Dewhurst
• Mould Flow Analysis using C-mold
• Sheet metal tooling analysis using Pam-stamp
• Computer aided process planning

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Task Activities

• Product Design Evaluation
• Based on the product received each group of
  student will apply different types of design
  analysis tools to evaluate the requirements
  including functions quality assembly so as to
  dictate the detail specification of the design.
  Detailed product engineering specification and
  virtual prototyping of the product are the
  required task results. 

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Task Activities

• Optimization and Design of process tooling and
  workplace
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• This task consists of the detailed evaluation of
  manufacturing process parameters and tooling
  design by applying virtual manufacturing tools
  such as virtual machining mould flow analysis
  and plant simulation. Deliverables include
  detailed process plans and specific design of
  tooling

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Assessment Method

• Student-centered study modules 30
• Task reports and presentations
• (including peer assessment) 60
• Individual portfolio 10

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Case Study - Rapid Product Development

• This case study deals the adoption of concurrent
  engineering can take advantages of information
  systems to synchronize the data and help to
  provide a virtual collaboration among the users.
• The case example illustrates how the isolated
  islands of functional unit can be grouped
  together through the adoption of concurrent
  engineering concept thus bringing an integrated
  view of a companys knowledge sources to an
  individuals desktop enabling better decision
  making by providing immediate access to key
  business information.
• The package is available on a CD with
  instructions for the students and guidance notes
  for the teacher.

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Case Study Web Integrated Product and Process
Planning

• This case example is designed to facilitate the
  real time input from potential customers
  regarding the kind of product they want allowing
  small quantities with dissimilar design of
  product.
• In addition the case example prototype is going
  to provide value chain information such as order
  placement and production logistics.
• Such prototype aims at quickly providing the
  right information to the right place at the right
  time in the right format throughout the
  inter-enterprise concurrent engineering processes
  to facilitate communication coordination
  control and integration of multi-enterprise
  concurrent product and process development.

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Self Learning Package - Integrated Design and
Planning for Assembly in a Virtual Environment

• This package concentrates on the area of design
  for assembly and virtual analysis.
• It includes a set of study guide and notes to
  help students to get familiarize with the topic.
• A case study using software to illustrate the
  concept of the analysis and typical results
  obtained including product redesign and
  improvement directions.
• An exercise based on a toy train model has been
  included and assessment of results are to be
  discussed.
• A number of short multiple choice questions are
  also available for students self evaluation in
  the form of a quiz.
• The package has been trial implemented in the
  last semester and was well accepted by the
  students.

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Learning Package on Virtual Design and Analysis
of Sheet Metal Forming

• This package concentrates on how computer assists
  the design and analysis of sheet metal forming.
• It includes ashow and movie to help
  student to have a general idea of the process
  the advantage of computer aided design with
  demonstration of professional software used in
  industry.
• A number of multiple choice questions are
  available to help student familiar with the basic
  concept of sheet metal forming.

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