Smart Factory Research Center

Digital Technologies – AI & Vision-Based Projects

Client: Heavy Vehicle OEM

Problem Statement / Project Scope:

• Objective: Design & validate automated processes in an assembly line environment.
• Focus Areas: Build line, defining robot kinematics, optimize robot path planning.
• Approach: Digital twin of the assembly line to simulate robotic motions, define joint constraints & ensure collision-free path.
• Outcome: Efficient line setup, improved cycle times, precise and synchronized robot operations.

Solution Highlights:

• Collision-Free Simulation
• Line Behavior Analysis
• Path Optimization
• Simulation Outcome

Client: Animal Care Industry

Problem Statement / Project Scope:

• Objective: Design & validate automated processes to improve productivity in manual workflows.
• Focus Areas: Identify process bottlenecks in manual processes.
• Approach: Compare improvements between manual & automated processes.
• Outcome: Optimize manpower and machine allocation to improve productivity and remove bottlenecks.

Solution Highlights:

• Process Simulation: Simulated existing workflow to locate bottlenecks affecting throughput.
• Automated System Analysis: Modeled proposed system to evaluate impact on cycle time, task distribution, & resource utilization.

Client: Automobile Industry (Pick & Place, Spot Welding)

Problem Statement / Project Scope:

• Objective: Automate spot-welding process with integrated pick-and-place operations.
• Focus Areas: Replace manual welding with robotic solution handling part loading, welding, and unloading in one cycle.
• Approach: Model station in Siemens Process Simulate, design robot paths, optimize cycle time, validate safety.

Solution Highlights:

• Simulated complete cell with loading, robotic welding, and unloading.
• Integrated welding gun models & programmed precise weld points.
• Coordinated pick-and-place & welding operations within one robot cycle.
• Optimized motion paths to reduce idle time.
• Validated collision-free operation & ergonomic material flow.

Client: Automobile Industry (Robotic Inspection Line)

Problem Statement / Project Scope:

• Objective: Automate post-paint car body inspection for higher accuracy & speed.
• Focus Areas: Replace manual inspection with robotic vision system for high production rates.
• Approach: Design robotic inspection concept, simulate in Siemens Process Simulate, optimize robot paths, validate cycle time & safety.

Solution Highlights:

• Developed robotic inspection line concept using industrial vision systems.
• Simulated inspection process ensuring robot reachability, accessibility & cycle time validation.
• Integrated virtual camera model to mimic actual vision inspection and lighting conditions.
• Validated safety zones, robot paths, and collision-free operation before deployment.

Client: PCB Manufacturing

Problem Statement / Project Scope:

• Objective: Create digital twin of PCB assembly line to identify bottlenecks & improve process flow efficiency.
• Focus Areas: Model full line from material loading to final assembly, detect capacity constraints, optimize equipment utilization.
• Approach: Use Tecnomatix Plant Simulation to replicate real process, analyze throughput & machine utilization, locate bottlenecks, test improved layouts & sequencing strategies.

Solution Highlights:

• Built digital twin of PCB assembly line including SMT machines, inspection & packaging stations.
• Simulated real process data to ensure accuracy.
• Used throughput & utilization analysis to locate bottlenecks.
• Modeled alternate process flows to reduce waiting times.
• Validated layout changes for improved material handling & cycle time.