Methodology for Rationalization of Pre-Production Processes Using Virtual Reality Based Manufacturing Instructions

Abstract

This article deals with the rationalization of manufacturing processes within the product life cycle with emphasis on the pre-production phase of production. A new methodology for evaluating the applicability of modern visualization tools in manufacturing processes is presented. This methodology includes a modified Z-score for categorizing manufacturing processes and has been validated by the successful implementation of 10 real projects. Ultimately, the methodology provides a practical decision-making aid for manufacturing companies in deploying such Computer Aided Instruction tools. For the pre-production phase of products and their development, the possibilities of using modern visualization tools to support CAD instructions and assembly instructions are being explored. These modern visualization tools are video tutorials, augmented reality tutorials and virtual reality tutorials. This paper explores the use of these tools for rationalization of pre-production processes. A methodology was designed to select the most appropriate tool for rationalizing process execution in preparation for production. The functionality of the methodology was verified by applying the methodology in industrial practice and subsequent implementation of the recommended solutions. The methodology was validated by testing key combinations that can arise based on the methodology directly in the operations of manufacturing companies. A total of 10 implementations in real production processes were tailored to this study and carried out over 2 years and the functionality of the methodology was confirmed (that consisted also of a new software development). It was found that there is a dependency between the visualization tools chosen to create the instructions in the context of organizational production preparation and the nature of the production processes.