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Description:
In the automotive industry, markets are demanding more product models, derivatives and extra equipment with shorter life-cycles. Due to these effects, planning of manual assembly is becoming more complex and diverse. With the current mostly physical mock-up production validation methods, these changes cause considerable increases in production planning costs, product preparation time and and put required quality levels at risk. The use of virtual assessment methods during the production validation phase is a promising countermeasure for these effects. As of yet, there is no holistic view on virtual production validation in the literature since related publications either offer self-contained, practical approaches or theoretical constructs without direct applicability. In order to bridge this gap, this doctoral thesis focuses on the analysis, development, integration and evaluation of collaborative, virtual methods for assessments of manual assembly processes in the manufacturing industry. This research focuses on the question whether collaborative virtual environments can support production validation workshops, so that verification criteria can be assessed in the same quality, less time and with lower costs compared to hardware-based workshops. A new system is being developed and proposed, called the "Virtual Manufacturing Station" (VMS). It is a framework for holistic virtual production validation. The VMS consists of a multi-display environment, sensors and software components so that it can be used in interactive, collaborative, virtual production validation workshops. In order to provide production validation engineers with such a virtual framework, six theoretical key properties are derived for the VMS: "collaborative virtual environments", "multi-user support", "original size visualization", "natural user interfaces", "integration of physical and digital mock-ups" and "asymmetric/symmetric output." This theoretical framework is based on four research areas with each contributing to at least one of the ...