AES Creates Production-Ready Facility 5 Times Faster with Dassault Systèmes PLM Solutions

“Over the past five years, we have been able to speed up the time it takes to complete facility engineering and design by at least a factor of five,” said Masahiko Nakazono, manager of AES Digital Engineering Office. “This is partly due to the improved skills of our engineers, but the efficiency and productivity gains that the CATIA and DELMIA solutions have given us are equally important.”

AES has been using CATIA and DELMIA extensively in its entire process flowfrom factory planning to production ramp-up. For stamping and body-in-white processes, AES has used DELMIA software, as well as for manufacturability and feasibility tests, simultaneous engineering, and basic and detailed design tasks including robot applicability simulations. In simulations designed to examine the applicability of robots to specific processes, AES directly imports 3D models created with CATIA into DELMIA Robotics and then evaluates possible spot welding sequences to help in the planning of the welding processes. When adapting an existing production line to new car models, these software tools are also employed to check whether the existing robots and welding guns are applicable to the new process.

To assure greater precision of the robots' movements, it is critical to understand exactly how the robots move, so the jig designs can be optimized. Conducting simulations with DELMIA while designing jigs with CATIA allows any errors to be identified and corrected at the same time. "That is the most significant advantage of using DELMIA and CATIA together, and no competing products can emulate them," says Masahiko Nakazono. Implementing a simultaneous engineering strategy for a recent Chinese auto manufacturer, AES’ conceptual designs were compared to the client’s 3D models, allowing 80 to 100 design flaws to be identified within two months. This allowed direct feedback to the designers who could make the corrections prior to prototype build.

AES also carries out offline programming of robot paths using personal computers. Critical in this process are the actual measurements of the shop floor, including the relative positions of equipment and the shapes and sizes of obstacles. For offline programming tasks, AES uses DELMIA Robotics and 3D laser scanning technology to create a digital model that is tightly correlated with the actual shop floor. When the process design is evaluated and optimized through these simulations, the results are converted into machine control programs and downloaded to each piece of equipment.

In addition to the time savings, the accuracy of the checks and evaluations performed during the early planning stage and after the completion of jig designs has improved significantly. “The intricate timing for lock-and-release among multiple robots is made clearly visible, and it takes only a short while to check and verify the timing even when a large number of robots are involved," Nakazono says.

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About Dassault Systèmes

As a world leader in 3D and Product Lifecycle Management (PLM) solutions, Dassault Systèmes brings value to more than 115,000 customers in 80 countries. A pioneer in the 3D software market since 1981, Dassault Systèmes develops and markets PLM application software and services that support industrial processes and provide a 3D vision of the entire lifecycle of products from conception to maintenance to recycling. The Dassault Systèmes portfolio consists of CATIA for designing the virtual product - SolidWorks for 3D mechanical design - DELMIA for virtual production - SIMULIA for virtual testing - ENOVIA for global collaborative lifecycle management, and 3DVIA for online 3D lifelike experiences. Dassault Systèmes’ shares are listed on Euronext Paris (#13065, DSY.PA) and Dassault Systèmes’ ADRs may be traded on the US Over-The-Counter (OTC) market (DASTY). For more information, visit http://www.3ds.com.

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