Digital Twin Technology: - A Manufacturing Quality Perspective

Get Connected: When CAE Simulation Meets Artificial Intelligence
Deep Learning Enhanced Digital Twin for Closed-loop In-Process Quality Improvement
DIGITAL TWIN TECHNOLOGY

- A MANUFACTURING QUALITY PERSPECTIVE -
Presented by: Professor Darek Ceglarek
Authors: Pasquale Franciosa, Sumit Sinha, Manoj Babu, Emile Glorieux, Darek Ceglarek
Digital Lifecycle Management (DLM) Research Group, WMG, University of Warwick, Coventry, UK
WindTwin: Open Day

TWI Ltd, Cambridge 28th January 2020
WMG @ University of Warwick, United Kingdom
WMG – an independent interdisciplinary academic department equivalent to Industrial & Systems Engg.
o An academic department of the University of Warwick

o Employing over 600 staff
o Working across research and education centres on the
Warwick campus
o Delivering education programmes in seven countries, and
collaborating globally on research and development
o An annual programme of £200m (industrial & in-kind
support)
o Strong relationships with over 1,000 global companies,
and supporting 1,800 SMEs
o Part of the HVM Catapult network HVM Catapult - Supports RTD &
technology maturation from concept
(TRL 3-4) to pre-production (TRL 6-7)
WMG @ University of Warwick, United Kingdom
New Development - ‘National Automotive Innovative Campus’ (NAIC)
• £150m investment - the biggest industrial & private sector investment in any UK university
(2017)
• A 33,000m2 collaborative research environment
• Unique infrastructure & national focus for R&D addressing UK Automotive Council agenda
• Creating 1,000 & attracting 3,000 further R&D jobs
• Bringing global R&D of major Tier 1 suppliers to co-locate
Supporting RTD and technology maturation from concept (TRL 3-4) to pre-
production (TRL 6-7)
DIGITAL LIFECYCLE DEEP LEARNING ENHANCED DIGITAL TWIN FOR
MANAGEMENT (DLM) CLOSED-LOOP IN-PROCESS QUALITY CONTROL & IMPROVEMENT
DLM research & technology development provides a transformative framework integrating Industry 4.0 enablers such as big data, cloud computing, robotics and AI:
- To create precise digital twins with capabilities to integrate data from interconnected systems with multi-disciplinary simulation of products & processes.
- To achieve resilient performance in production systems such as predict behaviour of process machinery to either optimise existing equipment for increased productivity & quality; or
introduce new equipment into an assembly line with minimum disruption.
GOAL Manufacturing
Towards Near-Zero Defects Closed-loop in-process (CLIP) quality improvement
CAE Simulations
Quality Defects Variation Response Method (VRM)
Design Simulation tools
System (1) To support system optimisation
Takes as input a set of Gives as output a (2) To improve process capability
system response
control parameters
(3) Variation reduction
Constraints such as
specification limits
Artificial Intelligence
Data Deep learning for Manufacturing
Quality Improvement tools
Challenges: (1) To support system optimisation
System (2) Intelligent root cause analysis of defects
Cell design with capabilities to simulate
‘production parts’ Control parameters Given the output is (3) Preventive control actions
have to be estimated known
Quality Improvement with capabilities for Constraints such as
quality defects Root Cause Analysis (RCA) specification limits
What we do? Framework AI tools Business value

Digital Twin for rapid scaling-up & deployment of new technology
• Shorten lead time by.
• Increasing Right-First-Time
Product & Process Smart Connected Factory Products in Field
Design • Rapid deployment of new process
Objective 1: ‘Right First Time’ Objective 2: Real-time optimization of Goal: technologies.
Towards Resilient System quality & operations performance Towards Zero-defects
Quality Data
• Reduction of installation and commissioning
In-use data
time & cost.
Monitoring Device analytics
2 in closed-loop In-line monitoring • Shorten ramp-up time by.
Quality in Digital Multi-disciplinary • Shortening Mean-Time-to-Detection (MTTD)
3 closed-loop
RCA / CAPA
Lifecycle Defect Simulator of quality defects
Management
• Shortening Mean-Time-to-Resolution
Simulations System (MTTR) ) of quality defects
1 in closed-loop Configurator
• Improved quality (6-sigma)
Enterprise Analytics • Applications: automotive,

aerospace, consumer goods &
others.
For more information: Prof. Darek Ceglarek; Prof. Pasquale Franciosa, {d.j.Ceglarek, p.Franciosa}@warwick.ac.uk

Simulation Digital Twin for rapid scaling-up & deployment of new technology
1 in closed-loop • Shorten lead time by.
• Configuration, optimization & control of assembly process with • Increasing Right-First-Time
deformable parts from design-to-production . Product & Process Smart Connected Factory Products in Field
• Digital twin with embedded CAE simulations Objective 1: ‘Right First Time’ Objective 2: Real-time optimization of Goal: technologies.
• Multi-disciplinary optimization of system performance & configuration Towards Resilient System quality & operations performance Towards Zero-defects
Quality Data
In-use data
time & cost.
Monitoring
2 in closed-loop 2 Monitoring
in closed-loop
Device analytics
In-line monitoring • Shorten ramp-up time by.
Quality in Digital Multi-disciplinary • Shortening Mean-Time-to-Detection (MTTD)
3 closed-loop
RCA / CAPA
Lifecycle Defect Simulator of quality defects
Management
Quality
3 in closed-loop • Improved quality (6-sigma)

others.

Quality Data
In-use data
time & cost.
Monitoring
in closed-loop
Device analytics
• In-line & In-process quality monitoring to accelerate RCA –incl. off-line
& in-line programming of robotic 3D scanner; Quality in Digital Multi-disciplinary • Shortening Mean-Time-to-Detection (MTTD)
3 closed-loop
RCA / CAPA
Defect Simulator of quality defects
• In-use data from intelligent assets & 3rd party devices. Lifecycle
Management
• Statistical Quality Control for Point-Clouds & big data. • Shortening Mean-Time-to-Resolution
Quality

others.

Quality Data
In-use data
time & cost.
Monitoring
in closed-loop
Device analytics
& in-line programming of robotic 3D scanner; Quality in Digital Multi-disciplinary • Shortening Mean-Time-to-Detection (MTTD)
3 closed-loop
RCA / CAPA
Defect Simulator of quality defects
• In-use data from intelligent assets & 3rd party devices. Lifecycle
Management
Quality
• Data-driven Root Cause Analysis (RCA) of quality (6-sigma & No-Fault-
• Applications: automotive,
Found) defects using in-line and in-process data. Enterprise Analytics
• RCA-driven Corrective & Preventive Actions (CAPA).
others.
• CAPA-driven continuous improvement.
• Multi-physics simulator of manufacturing defects.
What we do? Examples AI tools Business value

1 Simulation Rapid scaling-up & deployment of new technology • Shorten lead time by.
in closed-loop
deformable parts from design-to-production . Digital twin Genetics Algorithms
CAE Simulators embedded Polynomial Chaos • Rapid deployment of new process
• Digital twin with embedded CAE simulations & VR (TRL 3-4) into digital twin & VR Rule-based systems technologies.
• Multi-disciplinary optimization of system performance & configuration
time & cost.
Monitoring
2 in closed-loop
• Shorten ramp-up time by.
& in-line programming of robotic 3D scanner; Lab demo Scale-up simulator & Fuzzy models
• Shortening Mean-Time-to-Detection (MTTD)
Spatio-temporal models
• In-use data from intelligent assets & 3rd party devices. (TRL 6) In-process/inline monitoring of quality defects
(MTTR) ) of quality defects
Quality
Found) defects using in-line and in-process data. Pre-production
RCA and CAPA Convolutional Neural Nets aerospace, consumer goods &
pilot trials simulator and controller Reinforcement learning others.
(TRL7)

Simulation AI for rapid scaling-up & deployment of new technology
1 in closed-loop CAE Simulators embedded into digital twin & VR
• Configuration, optimization & control of assembly process with Fixture Robotic Laser Welding • Increasing Right-First-Time
deformable parts from design-to-production . Genetics Algorithms
Polynomial Chaos • Rapid deployment of new process
• Digital twin with embedded CAE simulations Rule-based systems technologies.
• Multi-disciplinary optimization of system performance & configuration Digital twin
& VR (TRL 3-4) • Reduction of installation and commissioning
time & cost.
Monitoring
2 in closed-loop
& in-line programming of robotic 3D scanner; Lab demo Scale-up simulator & • Shortening Mean-Time-to-Detection (MTTD)
• In-use data from intelligent assets & 3rd party devices. (TRL 6) In-process/inline monitoring of quality defects
Quality
RCA and CAPA aerospace, consumer goods &
pilot trials simulator and controller others.
(TRL7)

time & cost.
Monitoring
2 in closed-loop Scale-up simulator & In-process/inline monitoring
• In-line & In-process quality monitoring to accelerate RCA –incl. off-line Scale-up Sim In-process In-line
Fuzzy models
& in-line programming of robotic 3D scanner; • Shortening Mean-Time-to-Detection (MTTD)
of quality defects
• In-use data from intelligent assets & 3rd party devices.
Lab demonstrator (TRL6)
• Statistical Quality Control for Point-Clouds & big data. System tested on ~80 parts
Quality
RCA and CAPA aerospace, consumer goods &
pilot trials simulator and controller others.
(TRL7)
DIGITAL LIFECYCLE ARTIFICIAL INTELLIGENCE (AI) APPLICATIONS IN MANUFACTURING:

time & cost.
Monitoring
2 in closed-loop Scale-up simulator & In-process/inline monitoring
• In-line & In-process quality monitoring to accelerate RCA –incl. off-line Scale-up Sim In-process In-line
Fuzzy models
& in-line programming of robotic 3D scanner; • Shortening Mean-Time-to-Detection (MTTD)
of quality defects
• In-use data from intelligent assets & 3rd party devices.
Lab demonstrator (TRL6)
• Statistical Quality Control for Point-Clouds & big data. System tested on ~80 parts
Quality
RCA and CAPA simulator and controller
Fault ID RCA CAPA • Applications: automotive,
Found) defects using in-line and in-process data.
Convolutional Neural Nets aerospace, consumer goods &
Pre-Launch Launch 1 st shift 2 nd shift
Reinforcement learning
6-sigma Quality
others.
• CAPA-driven continuous improvement. Pre-production pilot trials (TRL7)
• Multi-physics simulator of manufacturing defects. System tested on ~3000 parts New production Launch
2018 Innovista Award from

JLR for the Most
Innovative Piloted
Technology
Closed-loop In-Process Quality Improvement 1
Simulations
in closed-loop
Simulations in Closed-loop
Determining optimum fixture design for a batch of non-ideal parts
Off-line
programming of Laser Welding
Fixture/jigs robotic joining and process parameters
handling
Video explaining design optimization posted on the Youtube – RLW Navigator
Simulations
in closed-loop
Determine optimum laser parameter selection
Off-line What does it do?

Fixture/jigs
programming of Laser Welding (1) Definition of optimum process
robotic joining and process parameters
handling parameters(i.e., power, speed), based
on defined output criteria (weld
quality, cycle time, etc.)
(2) Automatic identification of feasible
process
windows
Automatic process parameters selection for part-to-part gap bridging

Gap= ~0.0 mm Gap= ~0.4 mm Gap= ~0.8 mm
AA5182; 1.5 mm to 2.2 mm; 4 m/min; 3.8kW (avg power)
Simulations
in closed-loop
ROBUSTNESS: Automatic process parameters selection for part-to-part

Gap= ~0.0 mm gap ~0.4
Gap= bridging
mm Gap= ~0.8 mm
Off-line
programming of Laser Welding
Fixture/jigs robotic joining and process parameters
handling
AA5182; 1.5 mm to 2.2 mm; 4 m/min; 3.8kW (avg power)

SCALABILITY: Capability for Scaling process parameters for varying welding speed
Simulations
in closed-loop
Industry challenges: Off-line

programming of Laser Welding Business Value:
• Multi-disciplinary ‘simulation analytics’ to Fixture/jigs robotic joining and process parameters
configure, optimize & control assembly handling • Improved interaction between
process from design-to-production. product and process design.
• Platform to integrate both product & process • Reduced engineering cost by
models with measurement data. 30%.
‘Right-First-Time’ Design of RLW: Application to SUV door assembly
• Applications: automotive, aerospace. process - eliminated more than 100 engineering changes which • Improved dimensional quality
affected a total of 22 tooling elements or stiches.
20%.
• Reduction of installation,
commissioning and time to
What we do: launch.
• Configuration, optimization & control of assembly process
• Rapid deployment of current or
with deformable parts from design-to-production.
new process (Remote Laser
• In-line monitoring to accelerate root cause analysis (RCA). Welding, RLW).
Improvement obtained
• In-use data from intelligent assets & 3rd party devices. Current Industrial best-practice using the developed “multi-
• Data-driven Root Cause Analysis (RCA). disciplinary defect
simulator”
• Real-time optimization of machines, processes & plants.
• Machine learning for predictive capabilities.
Quality
in closed-loop
Quality in Closed-loop
What is it: Application:

• No-Fault-Found (NFF), a term for when faults No-fault found (NFF) root cause analysis at Motorola IDEN mobile phone
Business Value:
are known to exist yet evade efforts to manufacturing : • Airlines voted NFF "the most
identify them - a pervasive problem in high important issue" by the annual
tech Avionics Maintenance Conference
Results of the FRL Analytics
• Developed data analytics for NFF root cause Assembly process for NFF Battery failure in 2004. It continues to be among
analysis called Fault Region Localization (FRL) the top-most items AMC discusses
Boundary each year, but there are no
Region (BR) systematic root cause analysis
KC2: Specs Region

No-Fault-Fault approaches.
Region (NFFR)
• Mobile phone: 1 in 7 phones are
How is it unique: returned by customers – 60% have
• The developed NFF analytics for NFF root cause isolation Top-5 warranty faults NFF (WDSGlobal Report, 2006).
helped in elimination of a top-5 warranty problems in IDEN mobile phobne
one mobile phone OEM. Normal Region =
• The NFF analytics utilizes heterogeneous data: (i) Specs Region – BR – NFFR
Importance
warranty & (ii) manufacturing to identify both candidate
NFF Battery
Key Characteristics (KC1): Specs Region
NFF Audio
KCs explaining the NFF and also determine their fault
Display
Power off
and normal conditions windows .
Tx Defect
• Number of Variable: 170
• No. of Normal Sample: 1500 (as ‘*’)
• Faulty Samples: 20 (as ‘*’)
Warranty Faults
OUR RTD JOURNEY
RTD JOURNEY, IMPACT AND ACKNOWLEDGMENTS
TRL 2-4
CAE Solutions:
assembly simulations
TRL 4-6 (non-ideal compliant parts
Solutions+Demo VR with embedded CAE simulation
RLW for Steel
TRL 2-4
CAE Solutions:
In-process closed-loop
TRL 5-7-8 process quality control
Demo+Pilot In-line QC (GD&T) In-process QC (weld)
RLW for Al
Up-scaling
AR cell @WMG (tests on ~80 parts) IR cell @Solihull (tests on ~3000 parts
Engineering Game
Illustration
Multi-station Assembly Assembly stations In-line 3D Optical Scanner Station Root Cause Analysis
BIW
Frame w/ Cowl Roof
Cowl LH Frame w/ cross MBRs Cowl LH
BIW Frame RR Cross MBR
LH Side Fr Comp Roof Bows UB 3 Re-spot RH Side Frame
SF Outer&Inner A-Pillar Cowl Top UB Line 2
SF Outer Assem SF Inner Assem UB Line 2-0 Cowl Side
Through Side Fr. Outer RR W/H Outer Fr Door Hinge SF Inner Panel UB 1 Dash Fl Plenum
T-Lamp Mount. SF Outer Sub UB Line 1-1 Body Side Sills Dash Floor Plenum
SF Outer Panel B-Pillar Inner RR Door Locker RR Wheel House UB Line 1-0 Frt Floor Panel Dash Panel
RR Floor Ladder Front Rail Sub
Engine Compt 3 Frt W/H LH&RH
Engine Compt 2
Engine Compt 1
Frt Low Frt Xmbr
Frt Low RR Xmbr

Point-clouds data
Front Sill Hydroform Pnl
Key Product Characteristics (KPCs)
Off-line Laser Welding
Fixture/jigs programming process Robot Metrology Fixture
of robots parameters Simulation Modelling Modelling
New Applications of Isolate Defective KCC(s)

3D Optical Scanner Key Control Characteristics (KCCs)
Fixture design for a batch of non-ideal parts
KCC 1 KCC 2
SOVA Matrix
 KPC1   c11 c12  c1,m   KCC1  KCC 5
-In-line Monitoring c
 KPC  c22  c2,m   KCC2 
 2    21  
           
      KCC 3
 KPCn  n1 cn,1 cn, 2  cn,m  nm  KCCm  m1 KCC 4
Engineering Game
Illustration
Multi-station Assembly Assembly stations In-line 3D Optical Scanner Station Root Cause Analysis
BIW
Frame w/ Cowl Roof
Cowl LH Frame w/ cross MBRs Cowl LH
BIW Frame RR Cross MBR
LH Side Fr Comp Roof Bows UB 3 Re-spot RH Side Frame
SF Outer&Inner A-Pillar Cowl Top UB Line 2
SF Outer Assem SF Inner Assem UB Line 2-0 Cowl Side
Through Side Fr. Outer RR W/H Outer Fr Door Hinge SF Inner Panel UB 1 Dash Fl Plenum
T-Lamp Mount. SF Outer Sub UB Line 1-1 Body Side Sills Dash Floor Plenum
SF Outer Panel B-Pillar Inner RR Door Locker RR Wheel House UB Line 1-0 Frt Floor Panel Dash Panel
RR Floor Ladder Front Rail Sub
Engine Compt 3 Frt W/H LH&RH
Engine Compt 2
Engine Compt 1
Frt Low Frt Xmbr
Frt Low RR Xmbr

Point-clouds data
Front Sill Hydroform Pnl
Key Product Characteristics (KPCs)
Off-line Laser Welding
Fixture/jigs programming process Robot Metrology Fixture
of robots parameters Simulation Modelling Modelling
New Applications of Isolate Defective KCC(s)

3D Optical Scanner Key Control Characteristics (KCCs)
Fixture design for a batch of non-ideal parts
KCC 1 KCC 2
SOVA Matrix
 KPC1   c11 c12  c1,m   KCC1  KCC 5
-In-line Monitoring c
 KPC  c22  c2,m   KCC2 
 2    21  
           
      KCC 3
 KPCn  n1 cn,1 cn, 2  cn,m  nm  KCCm  m1 KCC 4
CAE Sim ulations Artificial Intelligence

Variation Response Method (VRM) Deep learning for Manufacturing
System
System
Gives as output a
Takes as input a set of
control parameters system response Root Cause Analysis Control parameters Given the output is
have to be estimated known
Constraints such as
Constraints such as
Thanks for your attention!
Any questions and/or comments?

Prof. Darek Ceglarek
Dr. Pasquale Franciosa
Acknowledgement: WMG, University of Warwick, UK

E-mail: d.j.ceglarek@warwick.ac.uk
p.franciosa@warwick.ac.uk
M: +44(0) 7824540721 / +44(0) 7440022523

T: +44(0) 24765 72681 / +44(0) 24765 73422
MAIN SOFTWARE CONTRIBUTORS AND DEVELOPERS:

Pasquale Franciosa (Warwick University), Abhishek Das (Warwick University), Manoj Babu (Warwick University), Emile Glorieux (Warwick University), Sumit Sinha
(Warwick University), Darek Ceglarek (Warwick University), Avishek Pal (Microsoft), Gerardo Beruvides (Hitachi), Vahid Shahi (University of Tehran), Ferdinando
Vitolo (University of Naples Federico II), Salvatore Gerbino (University of Campania), Achille Pesce (FCA), Chris Esposito (University of Naples Federico II)
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Get Connected: When CAE Simulation Meets Artificial Intelligence

DIGITAL TWIN TECHNOLOGY

Presented by: Professor Darek Ceglarek

WindTwin: Open Day

o An academic department of the University of Warwick

What we do? Framework AI tools Business value

• Improved quality (6-sigma)

Enterprise Analytics • Applications: automotive,

What we do? Framework AI tools Business value

Enterprise Analytics • Applications: automotive,

What we do? Framework AI tools Business value

Enterprise Analytics • Applications: automotive,

What we do? Framework AI tools Business value

What we do? Examples AI tools Business value

What we do? Examples AI tools Business value

What we do? Examples AI tools Business value

What we do? Examples AI tools Business value

2018 Innovista Award from

Determining optimum fixture design for a batch of non-ideal parts

Video explaining design optimization posted on the Youtube – RLW Navigator

Off-line What does it do?

Automatic process parameters selection for part-to-part gap bridging

AA5182; 1.5 mm to 2.2 mm; 4 m/min; 3.8kW (avg power)

Video explaining design optimization posted on the Youtube – RLW Navigator

ROBUSTNESS: Automatic process parameters selection for part-to-part

AA5182; 1.5 mm to 2.2 mm; 4 m/min; 3.8kW (avg power)

Industry challenges: Off-line

Video explaining design optimization posted on the Youtube – RLW Navigator

What is it: Application:

KC2: Specs Region

Frame w/ Cowl Roof

Cowl LH Frame w/ cross MBRs Cowl LH

BIW Frame RR Cross MBR

LH Side Fr Comp Roof Bows UB 3 Re-spot RH Side Frame

SF Outer&Inner A-Pillar Cowl Top UB Line 2

SF Outer Assem SF Inner Assem UB Line 2-0 Cowl Side

RR Floor Ladder Front Rail Sub

Engine Compt 3 Frt W/H LH&RH

Frt Low RR Xmbr

New Applications of Isolate Defective KCC(s)

Frame w/ Cowl Roof

Cowl LH Frame w/ cross MBRs Cowl LH

BIW Frame RR Cross MBR

LH Side Fr Comp Roof Bows UB 3 Re-spot RH Side Frame

SF Outer&Inner A-Pillar Cowl Top UB Line 2

SF Outer Assem SF Inner Assem UB Line 2-0 Cowl Side

RR Floor Ladder Front Rail Sub

Engine Compt 3 Frt W/H LH&RH

Frt Low RR Xmbr

New Applications of Isolate Defective KCC(s)

CAE Sim ulations Artificial Intelligence

Any questions and/or comments?

Acknowledgement: WMG, University of Warwick, UK

M: +44(0) 7824540721 / +44(0) 7440022523

MAIN SOFTWARE CONTRIBUTORS AND DEVELOPERS:

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