'Virtual Reality' Becomes Reality at Dana European Plant
4 March 1999
'Virtual Reality' Becomes Reality at Dana European Plant
TOLEDO, Ohio, March 4 -- Virtual reality has become reality
for Dana Corporation with the construction of a new plant in
Europe. The Perfect Circle Division of Dana is breaking ground for the new
plant this month. The plant was designed by groups in Europe and the division
office in Muskegon, Mich., supported through the use of virtual reality
technology at the Dana Technical Resource Park in Ottawa Lake, Mich.
"Virtual reality enables Dana to lay out new factories or redesign
existing plants more efficiently and in much less time than conventional
methods," said Ivan Stretten, manager of Virtual Engineering Services in
Dana's Advanced Technology Research Group. "The purpose is to build virtual
factories on the computer where they can be modified and optimized before they
are built. The new plant in Europe is an excellent example."
To optimize the layout of the plant, the new facility's plant manager,
engineering manager, architect, and manufacturing people spent two days at the
Dana Technical Resource Park in a special visualization room. The room is
equipped with a 10-foot screen and an extremely high-end graphics workstation
capable of projecting an image in 3-D when used with special shutter glasses.
During the two days, the group viewed and modified the layout of the new
plant, in real time, using a 3-D virtual reality model.
At least a hundred changes were made to the layout, ranging from modifying
the placement of individual machines to moving entire work cells to opposite
sides of the plant. The group estimates that during the two days it resolved
problems that would have plagued the plant for at least two years after
startup. Not only did they resolve potential problem areas, but they also
were able to optimize the process and material flow by quickly comparing
multiple layout scenarios.
Dana launched its first virtual reality pilot project in 1997. Elements
of the process have been used in such applications as Dana's Rolling
Chassis(TM) module produced for the Dodge Dakota sport-utility vehicle built
in Brazil. During 1998, numerous Dana divisions utilized the technology in
designing new manufacturing plants and processes for frames, hose, and piston
rings, in addition to modules and systems. "We have expanded our early work
from pilot to full plant layouts," said Stretten.
Stretten noted that one obvious advantage of the process is "speed to
market" because it enhances concurrent component and systems engineering.
Dana engineering and manufacturing groups can readily share common 3-D data,
simplifying the transition to virtual reality plant operations. "The 3-D
engineering data can be used directly in our virtual factories to assess the
best way to assemble, machine, or weld our product," said Stretten. "It also
aids Dana in meeting it's customer requirements as customers continue to
squeeze new-product development cycles."
Perfect Circle is an operating division of Dana's Engine Systems Group,
one of the company's seven global strategic business units. Dana Engine
Systems provides advanced, synergistic, total systems solutions to engine
builders worldwide. It combines the strength and capabilities of Victor
Reinz(R) gaskets and sealing products, Perfect Circle(R) power cylinder and
heavy-duty camshafts, fluid systems products, Glacier Vandervell(TM) engine
bearings, and Plumley powertrain components.
One of the world's largest independent suppliers to vehicle manufacturers
and related aftermarkets, Dana produces components and systems used on more
than 95 percent of the world's 700 million motor vehicles. Founded in 1904
and based in Toledo, Ohio, the company operates some 330 major facilities in
32 countries and employs more than 86,000 people. Dana reported sales of
$12.5 billion in 1998. Dana's Internet address is http://www.dana.com.