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
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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
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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
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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
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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
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Process
Design and
Optimization
Plant &
Workplace
Design
Typical Student Centered Study Modules
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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
1.
Product Design Evaluation
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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
2.
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
1.
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Student-centered study modules
Task reports and presentations
(including peer assessment)
Individual portfolio
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30%
60%
10%
Case Study - Rapid Product Development
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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 company's knowledge sources to
an individual's 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
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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.
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It includes a set of study guide and notes to help students
to get familiarize with the topic.
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A case study using software to illustrate the concept of the
analysis and typical results obtained including product
redesign and improvement directions.
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An exercise based on a toy train model has been included
and assessment of results are to be discussed.
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A number of short multiple choice questions are also
available for students' self evaluation in the form of a quiz.
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The package has been trial implemented in the last
semester and was well accepted by the students.
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Case study on a computer mouse
The boss of base make shorter.
The ribs of base move forward.
The hole of PCB make larger.
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Original
Modify
Learning Package on Virtual Design and
Analysis of Sheet Metal Forming
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This package concentrates on how computer assists the
design and analysis of sheet metal forming.
It includes a slide show 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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