Manufacturing Optimization Program for Sub-Millimeter Precision
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Solution Overview
Problem
Conventional manufacturing processes for complex, heterogeneous systems in sub-millimeter scales are inefficient due to their batch nature and high costs, making them unsuitable for low to medium production volumes, and require flexible manufacturing approaches that are challenging to set up and optimize.
Innovation Solution
A manufacturing optimization program, referred to as DfM2, which uses a concurrent engineering approach to quantify and optimize manufacturing parameters, including process yield, cycle time, and overall cost, by integrating a virtual reality simulator and redefined precision metrics, to assist in defining product and manufacturing system configurations for maximum yield and minimal cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional batch manufacturing processes are used for complex sub-millimeter systems, then manufacturing precision can be maintained, but productivity is low and cost per unit is high
Solution Approach 1:
The patent segments the manufacturing process into discrete, modular operations that can be independently optimized and executed. The system divides complex heterogeneous manufacturing into separate process modules (machining, assembly, testing) that can be performed in parallel or sequence, enabling high-volume production while maintaining sub-millimeter precision through dedicated functional stations.
Solution Approach 2:
The patent implements a universal manufacturing system with reconfigurable tooling and fixtures that can accommodate multiple product types and process requirements. The modular fixture system and interchangeable tooling allow the same equipment to maintain sub-millimeter precision across different manufacturing operations and product configurations, eliminating the need for dedicated precision equipment for each product variant.
2Productivity
If flexible manufacturing systems are implemented to increase productivity and reduce cost, then production volume and adaptability improve, but device complexity and implementation cost increase
Solution Approach 1:
The flexible manufacturing system is segmented into independent, standardized modules that can be configured through software rather than physical reconfiguration. Each module performs a specific function (machining, assembly, inspection) and can be programmed for different operations, reducing the complexity of managing flexibility while maintaining adaptability for low to medium volume production.
Solution Approach 2:
The patent replaces complex mechanical reconfiguration mechanisms with software-controlled programming and digital setup. The system uses computer-controlled positioning, programmable robot manipulation, and digital process parameters to achieve flexibility, eliminating the need for numerous mechanical adjustment components and reducing overall system complexity while maintaining adaptability.
3Manufacturing precision
If specialized tools and processes are used for specific manufacturing operations, then manufacturing precision is maintained, but adaptability to multiple operations decreases
Solution Approach 1:
The patent employs universal tooling systems with programmable capabilities that can perform multiple specialized operations. The reconfigurable fixtures and multi-functional end-effectors maintain sub-millimeter precision across different operations (machining, assembly, alignment) through software-controlled positioning and calibration, eliminating the need for dedicated specialized tools for each operation type.
Solution Approach 2:
The system maintains manufacturing precision across multiple operations by dynamically adjusting process parameters through software control rather than physical tool changes. The programmable system modifies positioning parameters, speed, force, and other process variables to optimize each operation while using the same physical equipment, thereby maintaining precision and adaptability simultaneously.
Data Source
AI summary
In one embodiment, a manufacturing process is optimized by enabling a user to specify a product to be manufactured, enabling the user to specify a manufacturing system for manufacturing the product, enabling the user to select parameters for the product and the manufacturing system, and automatically calculating manufacturing metrics for the manufacturing process based upon the user-specified models and user selections.