Technology overview: The technology of a digital factory and simulation realistically visualizes key elements of automatic manufacturing processes via 3D graphics so that a user can operate a virtual factory with the purpose of predicting and analyzing possible problems, performing design, verification, and correction of production methods in advance, and supporting optimized distribution of the factory’s resources, facilities, and human resources.
More specifically, the technology establishes a virtual factory based on a general drawing and facilities control codes without building actual production lines. In addition, operation of facilities can be performed/verified/corrected in advance by applying control logic of facilities to a virtual factory. The company has also secured a technology for creating 3D models containing kinematic/electrical information and physical sensors and for high-speed processing of large-volume 3D graphic data.
Furthermore, they have succeeded in conversion and simplification of facility design data for 3D simulation, performance of a safety/equipment collision test, creation of an operator-friendly process chart, alignment of simulated production methods and mechanical movements with control programs, and application of a physical PLC controller and HMI in use.

Industrialization: The 3D simulation technology was applied to thirty domestic/overseas new, modified, and mixed assembly lines of the Hyundai-Kia Automotive Group in order to verify their mechanical and electrical design, which reduced designed man-hour and improved the quality of control programs. Prior to actual set-up of a factory, virtual trial operation could minimize the period of the actual trial operation for preparing massproduction.
Furthermore, the technology could help to deal with frequent modification of production methods and mixed models, standardize PLC programs, and improve competitiveness compared with imported SW, and thus is being applied to the body, press, painting, and trim lines.
Currently, advancement of the technology is under way in response to requests of customers such as a phase shift circuit and monitoring. The technology has been applied to the standard PLC simulator of the global production technology training center of the Hyundai-Kia Automotive Group and to the integrated simulator and CPS simulator of the 3D virtual technology support center of the Korea Electronics Technology Institute.

Problem-solving in industrialization: Since domestic companies have introduced high-priced SW licenses, companywide application was not easy and customers had difficulty in using the virtual factory and simulator.
Requirements of customers were different depending on circumstances of each site, calling for continuous field tests to produce effective results. Thus, the company established a standardized template suitable for automobile manufacturing processes and achieved a virtual factory and simulation engineering services that match the site by up to 95%. These achievements were included in the regular process development procedures along with relevant services. The industrialization was largely divided into licenses and engineering services thereafter.
Based on the confidence that the smart factory technology is crucial to the future manufacturing industry, ceaseless R&D efforts were made in order to meet specific requirements of the site. The pilot and performance tests helped to reflect a customer’s know-how and specific production features of each industry. With the proprietary technology of the smart factory, the company offered effective management and standardization for control of old facilities and operation of processes.
The simulator was made more user-friendly while solutions for a simulator, controls design, operation, and monitoring as well as relevant training programs were offered to the global production technology training center of the customer.

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