Digital Factory is a 3D source for product information aimed to reduce design and manufacturing costs by creating a single set of plans, design models and work and product instructions, all integrated into a secure, collaborative platform.
With growing market interest in executive jet purchases, Embraer required flexible technology to support an agile manufacturing operation that responded quickly to market changes, while ensuring work was done in compliance with industry requirements.
Embraer's business challenge was to create a single PLM platform for its manufacturing and shop floor operations and to move all shop-floor data from a paper to an online environment.
"Our goal is to create a single manufacturing model to increase efficiency, reduce costs and offer a collaborative environment for designers, engineers, and floor workers to work as one team," said Alexandre Baulé, vice president, Information Systems, Embraer. "By following one product roadmap, we will react quickly and deliver the accuracy of data and perfection of processes so critical to ensure superior performance in our Phenom and Legacy 500 jets."
Working with Dassault Systèmes, Embraer launched two new design and manufacturing initiatives as part of its Phenom and Legacy 500 programs:
- Digital Factory (DF): Using CATIA and DELMIA for virtual design, production and manufacturing, Embraer has a 3D platform for process planning and detailing, workload balancing, costing, cycle time calculations, as well as a new 3D process for design validation and optimization. A 3D master source for product information known as "Model-Based Definition," is used by workers on the manufacturing shop floor to access design, data and work instructions with personal and tablet computers. ENOVIA's collaborative platform helps in the process planning and manufacturing simulation of aircrafts, with final plans published in 3DVIA and delivered on-line for use by shop floor workers as well.
- Manufacturing Execution System (MES): With the development of a new, common architecture, Dassault Systèmes paved the way to integrate an MES solution that allows shop floor workers and suppliers across many locations to access the latest 3D models and instructions real time, hence ensuring the accuracy of the final product and the set of instructions.
"Embraer is tapping into advanced technology solutions to help achieve significant savings by integrating key engineering, design and manufacturing operations into a single 3D model. These savings allow Embraer S.A. to re-invest resources in new industry opportunities and initiatives," stated Marcelo Lemos, general manager, Latin America, Dassault Systèmes. "Brazil is a country of historic contributions to the aviation industry. It is an incredible opportunity to partner with Embraer, a company driving that pioneering spirit."