Virtual Validation of Complete Facility Offers Immense Savings

Challenge

Automation Technology Group (ATG) required an integrated PLM solution for the development of its trend-setting plant engineering solutions.

Solution

ATG selected Dassault Systèmes’ PLM solutions for its complex projects including CATIA for virtual product design and DELMIA for virtual production planning.

Benefits

With its integrated DS PLM solution,ATG improved production processes,optimized product design, and achieved shorter lead times.

ATG Solutions GmbH, (Thüringen, Germany) a designer and manufacturer of production facilities and equipment, relies exclusively upon its DELMIA software solutions for validating its manufacturing facility and equipment efficiency. The digital manufacturing software is helping the company save time and money by identifying potential problems in the virtual world, prior to production.

 “Because of the ubiquity of CATIA in our industry design engineering, the seamless compatibility of DELMIA data is a huge plus,” says Torsten Hessland, CEO of ATG. “DELMIA allows us to integrate visualizations and simulations easily into previously existing plant and engineering designs without losing any time due to translation issues.”

 Working with SWJ Consult GmbH (Städe, Germany), an independent engineering company for planning and project management, ATG is able to create an entire factory or production facility in the virtual world of DELMIA.  Noted Hessland, “Without the DELMIA solutions, it would not be possible to create the necessary interfaces for system evaluation.”

 To accomplish its goal of proving out factory floor efficiency in the virtual world, ATG is currently implementing DELMIA DPM Body-in-White, Robotics, Human, and Automation solutions.  Together, these solutions allow ATG to create, modify and validate automotive body-in-white planning for lines and stations in a virtual 3D environment—inclusive of robotic workcell programming and human behaviors—prior to any physical production. Additionally, the virtual commissioning capabilities of DELMIA Automation solution merge the 3D virtual manufacturing models with the actual control systems and robot controllers. The company can then conduct and evaluate “what if” scenarios to optimize production, enabling them to get it right the first time. Any proposed changes to a plant floor layout can be explored beforehand in the virtual model of the plants.  

The strength of the CATIA/DELMIA combined solution is based upon the common data model, which allows for continuity of workflow to achieve immense time, quality and investment advantages.  “For example,” explains Dr. Bernd Hirthammer, CEO of SWJ, “when several robots are involved in the material handling of a component, we can simulate the process offline using DELMIA for maximum efficiency.  The accuracy of the solution then allows for easy transfer and upload of the program to the real-world equipment.”

 Currently, ATG is focusing on the development of new materials for carbon fiber technology.  “Given today’s focus on energy conservation through weight reduction, we are examining applications where steel or aluminum could be replaced with carbon fiber materials,” says Dr. Hirthammer.  “This is an excellent application of the DELMIA portfolio as we’ve found that our simulation results have been confirmed through real-world prototype testing.”

 About ATG Solutions GmbH

ATG Solutions GmbH is an extremely dynamic and innovative corporate group comprised of individual companies that focus on different business areas: the companies are ATG engineering GmbH, ATG mechanics GmbH, ATG electrics GmbH, and ATG plastics GmbH. As a leading solutions developer for PLM and digital production facility planning, the ATG Group can implement all aspects of planning and design engineering as well as virtual and physical installation of equipment and machinery. The company currently employs 46 people in Berka/Werra, Germany.  www.atg-solutions-group.com

 About SWJ Consult GmbH

As part of the SWJ Group, Stade-based SWJ Consult GmbH is a leading engineering services provider of general and digital production facilities planning in Germany for the automobile and aviation industries. Primary emphases are on digital planning for production facilities and manufacturing systems, PLM solutions consulting and implementation, industrialization of composite material technologies, and knowledge transfer among different branches of industry. SWJ Consult is a member of the CFK Valley Stade expert network and a certified partner of Dassault Systèmes. The SWJ Group consists of SWJ Engineering GmbH, SWJ Consult GmbH, IPF Engineering GmbH, and SWJPlan GmbH and employs approximately 70 people. Main facilities are located in Griesheim, Stade, and Bad Homburg, Germany. www.swj-consult.de, www.swj-engineering.de