Manufacturing Process Model

What is a manufacturing process model?

Manufacturing process models determine the most effective way to manufacture a product by simulating discrete manufacturing processes and routings (e.g., determine the most effective processes and routings to produce a high-volume part via injection molding based on criteria including cost). Companies use digital twins (3D CAD models) to simulate manufacturing processes to identify the most appropriate production process for cost, sustainability, and manufacturability.

What are the benefits of manufacturing process models?

The term Industry 4.0 reflects digital transformation in manufacturing, which includes the ability to simulate the entire product development process – from design to production. Manufacturing process models are an important element of this digitalization process.

Manufacturing process models evaluate cost, along with design for manufacturing (DFM) and sustainability. Product development teams can use this information to conduct “what if scenarios” to understand the effect of one seemingly minor change (e.g., how will using a different manufacturing process reduce waste or accelerate production?). This includes simulating multiple product design options, raw materials (and suppliers), factory equipment, processes, routings, and regional manufacturing cost differences.

What do manufacturing process models simulate?

Manufacturing process models simulate hundreds of manufacturing processes and associated variables such as production volume and machine type. Capabilities include:

Process capability and routing rules:

• Available process and routing selections
• Machine feasibility
• Routing rules
• Geometric cost drivers (GCDs) relationship rules

Manufacturing insights:

• Process cycle time calculation
• Material utilization
• Tooling costs
• Tool wear/life expectancy

How are manufacturing cost models and manufacturing process models different?

Companies use manufacturing cost and process insights to support their business goals (e.g., should I accelerate output at a slightly higher cost to meet immediate market demand, or should I select a lower-cost, lower-carbon option from a supplier with a longer production schedule to improve the bottom line?).

A manufacturing cost model is a systematic calculation to estimate all product manufacturing costs including:  materials, direct labor, production, and other overhead expenses. Manufacturing process models move beyond just cost analysis to also optimize products for sustainability, and DFM simultaneously in a single platform.

How are manufacturing process models used in digital manufacturing (digital transformation in manufacturing)?

A manufacturing process model is a type of digital twin used to simulate and model digital manufacturing (digital factory). A digital twin is a virtual representation (i.e., digital version) of a physical asset or process used to analyze and optimize product designs, manufacturing processes, factory efficiency, and other operations.

Digital twin technology broadly falls into the following three categories:

1. Digital Product Twins are 3D CAD models (virtual replicas) of physical products that include components and assemblies, along with overall product size and shape. Product development teams use simulation to see how design changes affect product quality, sustainability, cost, and manufacturability.
2. Digital Process Twins determine the most effective product manufacturing method by simulating manufacturing processes and routings. Companies simulate manufacturing processes using the digital twin to identify the most appropriate production process/workflow for cost, sustainability, and manufacturability.
3. Digital Factory Twins are virtual models of physical factories that include precise factory-specific production capabilities and detailed costs including labor, electricity, materials, and overhead rates across the globe. Companies use this smart manufacturing capability to help evaluate their CO₂e across their supply chain ecosystem (Scope 3) by creating a virtual representation of supplier factories and their own manufacturing locations.