Driving Performance with Digitalized Manufacturing - Dell Virtual Reality (VR)
At a glance
Focus: Driving Performance with Digitalized Manufacturing – Dell Virtual Reality (VR)
Challenge: Short product manufacturing lifecycles led to frequent new product introductions, and ramp-time to production was impacted by the training and skill development required for new or revised assembly tasks — revealing gaps in the organization's ability to meet productivity and delivery commitments during the initial stage of product launch.
Approach: Dell explored Virtual Reality (VR) as a tool for operator training to accelerate the learning curve and initiate training on new product assembly early in the process, independent of sample availability — using a Design Thinking methodology (Empathize, Define, Ideate, Prototype & Test) with a collaborative team of in-house engineers and a reputed engineering institute's VR experts.
Impact: The solution delivered faster time to market for new products and improved workmanship and product quality during the initial phase of product launch — achieved through a self-guided VR training environment built on a 3D model of the manufacturing assembly line, with embedded self-assessment and skill evaluation.
Dell International Services India Pvt Ltd
Dell Technologies provides customers of all sizes – including 98 percent of the Fortune 500 – with a broad, innovative portfolio from edge to core to cloud. Dell Technologies provides wide-ranging technology solutions including Dell client as well as Dell EMC infrastructure offerings that enable organizations to modernize, automate and transform their data center while providing today’s workforce and consumers what they need to securely connect, produce, and collaborate from anywhere at any time.
Business challenge
The following challenges were faced that led to the discovery of the problem -
Short product manufacturing lifecycle leading to frequent introductions of new products.
Ramp-time to production impacted by training & skill development required for new or revised product assembly tasks.
Discovery of gaps in organization’s ability to attain productivity & delivery commitments in initial stage of product launch.
Industry 4.0 solution
Explored Virtual Reality (VR) as a tool for operator training in:
Accelerating learning curve
Initiating training on new products assembly early in the process, independent of sample availability
Key steps involved in going from ideation to decision
DesignThinking methodology deployed: Empathize, Define, Ideate, Prototype & Test
Resource allocation
Collaborative team approach involving representatives from in-house engineering team & reputed engineering institute.
The roles and responsibilities of the teams were divided like -
Project scoping / requirement definition – Manufacturing Engineering team
Initial POC by partner (VR experts)
Iterative validation feedback between engineering teams and VR partner.
VR as a compliment to manual training:
Develop a virtual (3D) model of manufacturing assembly line, integrated with components and manufactured products
Self-guided VR training environment
Self-assessment and skill evaluation framework embedded in training environment
Leverage in-house products and services to develop VR solutions.
Key benefits
| Area | Outcome |
|---|---|
| Time & Speed | Faster time to market for new products |
| Quality | Improved workmanship and product quality in the initial phase of product launch |
Technologies used
Change management and implementation
The following risks were foreseen while embarking on solution development -
Technical
Visual accuracy of model
Accurate response to manual actions
Financial
Medium-level investment for hardware and software components
The technical risks were mitigated through iterative process, refinements after each version and financial risks were mitigated by leveraging in-house financing.