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In preparation for mass customization, for starters, Japanese and German tech research officials today committed to expanding their joint work to establish a “social-technical or maybe ‘cyber-social’ environment where ‘digital companions’ and production lines communicate with humans” working in manufacturing, Andreas Dengel said in an interview with Smart Manufacturing magazine here at the CeBIT (Centrum der Büroautomation und Informationstechnologie und Telekommunikation) fair.

In the aerospace world, as in all sectors of manufacturing, the race is on for faster, more automated and connected machining operations. Aerospace builders have steadily pushed for more automotive-like automation over the past several years in order to improve productivity and more effectively handle large order backlogs in commercial aviation.

Today, the ideal factory can achieve levels of self-controlling (and perhaps self-learning) production processes, in which production reacts autonomously to changes or faults and takes appropriate measures.

Immersive visualization in the manufacturing world has proven its value time and time again during design reviews, proof-of-concept validation, and customer engagement, decreasing time to market and minimizing risk. Organizations are experiencing faster buying cycles, decreased time-to-market, and minimized risk as they optimize designs in virtual space.

New work materials are developed continually to improve the capabilities of finished parts, making them lighter and stronger, among other properties. When these materials catch on, cutting tools must adapt to their often challenging properties.

The ongoing digital transformation of manufacturing comes baked-in with many uncertainties, and the automotive business is no exception.

Challenged by an increasingly niche-oriented automotive market, The Chrysler Group (Auburn Hills, MI) must increase the number of models it offers while decreasing its capital investment. The company plans to offer 50% more models in 2009 compared to 2004, according to John Felice, VP of manufacturing, technology and global enterprise for Chrysler.

Automation in manufacturing is more important than ever, reducing costs and improving quality. While it is important in assembling cars, machining engines, or drilling holes in airframes, is it important to metrology operations as well? “Absolutely,” explained Michael Kleemann, engineering manager VRSI (Plymouth, MI).

Shops today must track or measure their manufacturing operations to improve them. This need drives the growing use of MTConnect—an open, royalty-free protocol for extracting data from practically any piece of equipment, including machine tools and other manufacturing systems. The integration of MTConnect is a major undertaking, and can be a bit challenging unless certain preparations are made ahead of time.

It is common sense—a vehicle that weighs less requires less fuel to move it. A number of studies show that reducing the mass of a vehicle by 10% results in anywhere from 4.5 to 6% better fuel economy—well worth the effort.