3D manufacturing innovation  revolutionary change in japanese manufacturing with digital data

Tasks in Manufacturing and Ideal Uses of IT

In today's competitive landscape, companies prioritize the establishment of high-speed development systems to minimize the time from product conception to market launch This objective is crucial for various manufacturers, ranging from digital home appliances with short product lifecycles to automotive industries The ultimate goal is to achieve speed, enabling businesses to be the first to introduce attractive products that meet emerging consumer needs Rapid identification of user demands and swift production processes are essential, as shorter development times often lead to reduced costs and enhanced market competitiveness.

The manufacturing industry is increasingly adopting IT solutions to boost competitive strength, with a significant focus on reducing costs A key driver for this rapid development is the implementation of 3D CAD technology in product development, which aims to enhance development speed and efficiency.

The rapid pace of development is leading to significant challenges, including overwhelmed manufacturing sites and exhausted personnel, which limits their ability to focus on next-generation technologies Issues such as insufficient time for staff training and reliance on outsourcing hinder the retention of accumulated knowledge within companies This has contributed to a decline in manufacturing quality, particularly evident in Japan To address these challenges, it is crucial to establish robust IT infrastructures that support design and manufacturing teams However, current 3D CAD systems often complicate operations rather than streamline them, placing additional burdens on design engineers Despite substantial efforts to generate 3D data, its practical applications remain limited, raising concerns about the value relative to the labor invested in its creation.

Japan is recognized as a broadband internet superpower, ranking fourth globally in household broadband penetration rates as of the end of 2005, following Korea, The Netherlands, and Sweden The country boasts some of the world's most advanced IT infrastructures, providing high-speed internet access through its extensive broadband networks.

In March 2006, the World Economic Forum revealed that Japan ranks 16th in the response index for IT infrastructure, which measures the contribution of IT to economic growth This ranking highlights Japan's underutilization of its world-class IT infrastructure, making it essential to improve this response index for enhanced economic performance.

Japan is poised to enhance its IT infrastructure index in the manufacturing sector, leveraging its global leadership in 3D data utilization The country is developing unique software tailored to its manufacturing practices and culture, which supports key processes such as basic design, production in local plants, and global product release By effectively harnessing 3D data alongside its advanced IT infrastructure, Japan's manufacturing industry can significantly bolster its competitive strength.

Current Situation of Use of IT in Manufacturing

Figure 1.1 shows how manufacturing companies invested in IT in 2004 and 2005

The significance of 3D CAD, CAM, and CAE technologies is immense, with 70% of companies already embracing 3D design, manufacturing, and analysis This widespread adoption highlights the critical role of 3D design in enhancing efficiency and innovation across industries, indicating a substantial potential for future growth in this area.

The adoption of Product Data Management (PDM) systems in manufacturing has significantly increased, rising from 40% of companies utilizing PDM in 2004 to over 50% in 2005 This growth highlights the importance of effective design data management in the industry.

The rise of 3D design is becoming the norm, leading to a significant increase in the volume of 3D data Concurrently, systems are being developed to effectively manage this growing data Collaboration tools are experiencing rapid growth, with nearly 30% of companies adopting them by 2005 This trend aims to leverage accumulated 3D data for enhanced collaboration, signaling the beginning of widespread integration.

Figure 1.1 Manufucturing industry investment in IT infrastructure

Figure 1.2 Increase in 3D CAD usage

The adoption of information technology (IT) in the manufacturing industry is crucial for enhancing competitive strength, particularly through efforts to share and reuse information While the use of 3D data is becoming more prevalent, similar to 2D CAD, 3D models are still underutilized for conveying information, with 2D drawings remaining the primary method To effectively communicate design information to the production process, manufacturers often create 2D drawings from 3D models.

3D models often fall short in conveying comprehensive design information, as they primarily represent shapes rather than detailed specifications This limitation means that essential product information, which reflects design intent and testing details, cannot always be fully integrated into these models Consequently, there is a critical need to supplement 3D representations with additional data to ensure accurate communication of design concepts.

The advancement of 3D CAD technology is addressing the need for converting dimensions and annotations into lightweight 3D data, enabling easier integration and manipulation Additionally, editing software can be utilized to enhance this information further.

The accurate exchange of 3D model shapes between different CAD systems is often hindered by discrepancies in accuracy and modeling methods, leading to errors and unrealistic models To address these challenges, there is an increasing focus on improving product data quality (PDQ) for CAD models, with various PDQ software tools already available in the market Additionally, barriers to effective 3D data utilization include a lack of development processes based on 3D models and difficulties in viewing them These issues arise from the inherent nature of design and production processes, necessitating top-down business reforms to fully implement digital processes.

Figure 1.3 Drawings are still being commonly used to communicate information

Strategies to Secure Competitive Advantage

Effective collaboration between departments is essential for optimizing production activities that utilize 3D data Reliable databases and efficient distribution mechanisms are crucial for ensuring that the necessary 3D data reaches the right personnel The rapid advancement of lightweight 3D data formats is addressing existing system challenges To fully leverage the benefits of accumulated 3D data, business processes within the company must be adapted to enhance overall work efficiency.

1.3 Strategies to Secure Competitive Advantage and Use of 3D Data

In his book "IT Doesn’t Matter," Nicholas Carr argues that information technologies have matured and become widely accessible, with standardized computer technologies and decreasing prices As a result, effectively utilizing IT has become a trivial concern, and it no longer provides a competitive edge for companies The availability of common software for email, internet, word processing, and spreadsheets has made the business landscape more convenient, diminishing the role of such tools in corporate differentiation Similarly, computer-aided design (CAD) is following this trend, evolving into a commodity.

The effective utilization of accumulated 3D data has the potential to enhance the competitive strength of the manufacturing industry Advanced companies in this sector are actively experimenting with innovative technologies to leverage this data for improved efficiency and productivity.

Figure 1.4 Barriers for using 3D models

The adoption of IT, particularly 3D data, by the manufacturing industry is significantly enhancing competitive strength Companies are establishing a foundation for competitive advantage through strategies focused on cost performance and differentiation Cost performance strategies aim to deliver products and services at lower costs, supported by continuous improvements in manufacturing processes The effective utilization of 3D data has led to increased work efficiency, exemplified by the automatic generation of product manual illustrations from 3D data, which are more cost-effective and consistent in quality than traditional hand-drawn illustrations Thus, leveraging 3D data plays a crucial role in achieving cost advantage strategies in manufacturing.

Figure 1.6 Corporate competitive strategies and use of 3D data

Figure 1.5 Information technologies becoming a commodity

Trends in Lightweight 3D Data Related Technologies

Differentiation strategies focus on creating new market rules through innovation, which often requires the integration of IT to enhance collaboration between design and manufacturing The application of 3D data varies by business type and can be leveraged in innovative ways, serving as a competitive advantage In Japanese manufacturing, known as "MONOZUKURI," which encompasses both product ("MONO") and production ("ZUKURI"), 3D data plays a crucial role in streamlining processes It can minimize unnecessary tasks in design and production, allowing employees to shift from manual labor to intellectual innovation Furthermore, 3D data facilitates the visualization of information, enabling the accumulation of valuable feedback from the manufacturing site, which in turn fosters further innovation.

1.4 Trends in Lightweight 3D Data Related Technologies

The trends in lightweight 3D data technologies are increasingly significant in manufacturing, particularly with the adoption of XVL technology, which originated in Japan Major CAD vendors in Europe and the USA are recognizing the advantages of lightweight 3D data and are beginning to invest in this area For instance, Dassault Systemes from France has licensed XVL technology from Lattice to develop the lightweight 3D format known as 3D XML Their 3D CAD software, CATIA, is widely utilized in the automotive and aerospace sectors Additionally, UGS in the USA is actively promoting lightweight 3D solutions, reflecting a growing trend in the industry.

Figure 1.7 Acquire competitive edge in manufacturing

8 1 Adoption of IT by Manufacturing Industry to Enhance Competitive Strength

The JT format is a 3D data standard that encompasses both polygon data for visualization and precision data for CAD data exchange Autodesk, the leading PC CAD company, advocates for the DWF format, which is designed for displaying lightweight 3D polygon data Various CAD companies promote their unique formats through engineering applications tailored to enhance data interoperability and visualization.

In 2006, Adobe introduced 3D PDF, enhancing the widely-used PDF format by incorporating Universal 3D (U3D), a lightweight 3D format developed by Intel, Adobe, and the 3D Industry Forum, and certified by ECMA This support for U3D allows 3D models to be displayed within PDF documents Initially, U3D utilized a polygon-based representation, which, while effective for quick geometry display, often resulted in large file sizes due to the high number of polygons required for smooth CAD surfaces The aim of creating a lightweight 3D format is to achieve high accuracy with smaller file sizes, leading to ongoing technological competition in the industry.

International standards in the realm of 3D graphics often struggle to gain traction, as seen with various standards like CORE, GKS, PHIGS, VRML, and X3D that failed to meet expectations This challenge can be attributed to the rapid evolution of technology, where established standards quickly become outdated.

Back to Figure 1.8 again The battle around the standardization of 3D is intensi- fying This battle differs from that around the standardization of videotapes, VHS versus Betamax, many years ago In the world of hardware, tapes without com- patibility cannot be played on a VCR In the world of software, as long as the data can be converted from one format to the other, applications will be able to read it Consequently, the essence of the problem of using lightweight 3D lies not just in the data format, but also in the applications for using the 3D data The quality of

Figure 1.8 Lightweight data technology flow

1.4 Trends in Lightweight 3D Data Related Technologies 9 the format affects the performance of the applications, but the applications must still meet end user needs

XVL is recognized as the most lightweight and accurate 3D format, and efforts are underway to enhance it by incorporating essential design information for manufacturing Key users of lightweight 3D formats include designers who create the 3D data and downstream users who previously had no interaction with 3D technology For lightweight 3D formats to be effective, they must encompass not only 3D shapes but also the non-geometric information necessary for downstream applications Additionally, these applications must be capable of processing both the 3D data and the accompanying information.

The rise of 64-bit PCs is a significant trend in the IT industry, particularly for CAD and CAE users who require enhanced processing capabilities for large-scale designs and analyses Unlike 32-bit PCs, which are limited to a 3-Gbyte virtual memory space, 64-bit systems offer an expansive 16-Tbyte capacity, making them essential for handling the increasingly large data sets in these applications While CAD manufacturers are beginning to introduce products optimized for 64-bit systems, typical users engaged in basic tasks such as emailing or document creation will find current PCs sufficient The transition to 64-bit technology will likely be gradual, contingent upon the affordability of hardware and the compatibility of software with 64-bit environments Until then, design departments at leading firms are equipped with 64-bit PCs to manage large CAD data, while the broader workforce will still rely on 32-bit systems to display this data, as widespread distribution of advanced 64-bit PCs remains unfeasible in the near future.

Figure 1.9 Impacts of 64-bit PCs

10 1 Adoption of IT by Manufacturing Industry to Enhance Competitive Strength

Lightweight 3D technology is increasingly important for accurately displaying large volumes of 3D data, especially on standard 32-bit PCs Formats like XVL have emerged to facilitate the efficient visualization of extensive 3D datasets, making them vital for businesses In recent years, the significance of lightweight 3D data has grown substantially within companies, highlighting its value in enhancing productivity and data management.

The cost-effectiveness of individual projects is significantly influenced by the accumulation of IT assets and their utilization Companies boasting a robust IT infrastructure tend to achieve higher profits from these projects compared to those lacking such resources This concept parallels the tool change process in manufacturing environments.

The construction of IT infrastructure is essential for preparing for process changes, enabling companies to achieve high-quality results with short delivery times and low costs Establishing standard IT strategies is crucial for businesses, particularly with the gradual implementation of 3D CAD and PDM systems Leveraging lightweight 3D data can enhance corporate competitiveness, making it vital for companies to accumulate this data, share it internally and with partners, and train key personnel in its use Ultimately, building robust IT infrastructures centered around 3D data is critical for success in the manufacturing sector.

Trend Toward Use of Lightweight 3D Data

The rise of the network society has enhanced information sharing across various sectors of the manufacturing industry, leading to significant changes in business processes However, 3D CAD data, essential for digital manufacturing, has not fully leveraged network technologies This is due to its large data volume and complex structures, which complicate integration with other networked data Despite the high costs associated with generating 3D CAD data, its application has been largely confined to the CAD/CAM domain, representing less than 10% of the overall IT industry.

The emergence of lightweight 3D data such as XVL is changing this situation Industry is increasingly trying to change the overall business mechanism by con- verting CAD data to lightweight 3D data This includes not only companies but also their partners and suppliers So what is the significance of the existence of this lightweight 3D data and how should it ideally be used?

Designs Based on 3D CAD to Full Use of 3D Data

3D data stands out for its simplicity, making shapes easily understandable for everyone, unlike traditional design drawings that often require specialized knowledge This intuitive grasp of shape through 3D displays enhances communication, positioning 3D data as a powerful medium While the Internet currently relies on text, images, 2D animation, video, and audio to convey information, the future lies in the integration of 3D data as a key communication tool.

3D data generation poses significant challenges, primarily due to its high costs The expense of 3D CAD is considerably greater than that of 2D data, and the added dimension of depth complicates its management Additionally, mastering 3D CAD demands both time and financial investment.

3D design has established itself as the standard across numerous industries, particularly in manufacturing, where 3D CAD is increasingly favored Design departments are actively gathering 3D data, making it essential for companies to leverage this data internally and with affiliated organizations.

The trend towards utilizing lightweight 3D data is reshaping communication with consumers Typically, a design department collaborates with ten times its production and product-related partners, who in turn engage with a hundred times more consumers.

Utilizing 3D data for communication with product-related partners and consumers has the potential to significantly transform the manufacturing industry's business processes By effectively reusing 3D data generated in the design department, downstream costs associated with creating new 3D data can be eliminated However, two key obstacles must be addressed to ensure widespread access to 3D data for all stakeholders.

1 3D CAD data is very large, and cannot easily be shared on the network

2 3D CAD systems to read the data are very expensive and complicated, and thus cannot be made available to everyone

To address these challenges, developers created lightweight 3D data formats and corresponding software viewers These lightweight 3D viewers typically encompass free tools for inspecting 3D shapes, as well as commercial products designed for measurement and interference calculations.

HTML, or Hyper Text Markup Language, is the foundational language for creating web pages, but it is increasingly being supplanted by XML, or eXtensible Markup Language XML offers a more versatile framework for representing a wide range of information, including complex 3D data structures and associated design and manufacturing details.

Integrating advanced 3D lightweight technology with XML can effectively address key challenges in accessing 3D data This approach enables the conversion of 3D CAD data into lightweight formats, allowing general users without CAD software to easily access and view 3D data through a simple viewer.

Lattice XVL leverages XML technology to generate a lightweight and precise web-friendly format for 3D CAD data This innovative approach enables the seamless sharing of lightweight 3D data across organizational boundaries Remarkably, XVL can reduce 50 MB of CAD data to just 500 KB, facilitating efficient data management and accessibility.

Figure 2.1 Use of CAD/CG data in downstream processes after conversion to lightweight 3D data

Why Lightweight 3D Data, not CAD?

Display of Very Large Data

In CAD design, multiple designers create parts that combine to form a complete product, often resulting in massive data volumes, particularly in the automotive and aerospace industries, where data can reach 20 Gbytes for cars and 5 Tbytes for airplanes However, CAD systems struggle to display such large datasets, with performance significantly declining once data exceeds several hundred megabytes Typically, industrial machines consist of 3,000 to 5,000 parts, while printers and photocopiers may contain 5,000 to 8,000 parts; beyond 5,000 parts, CAD display responses deteriorate sharply, making real-time data sharing impractical Lightweight 3D solutions, such as XVL, can effectively address these challenges, enabling the display of CAD data exceeding 10 Gbytes.

3D data plays a crucial role in documentation by enabling the easy creation of technical documents through generated illustrations The rapid advancement of applications for producing illustrations from lightweight 3D data enhances this process Additionally, software for creating and distributing 3D animations is now widely available It's important to consider that the end users of these animations typically are not CAD users, necessitating the availability of affordable and user-friendly viewers Since many of these users operate on budget-friendly PCs that are slower and have less memory than CAD workstations, lightweight 3D viewers must deliver strong performance on lower-specification machines.

2.2 Why Lightweight 3D Data, not CAD? 15

There is a growing trend to utilize lightweight 3D data instead of traditional drawings for conveying information throughout the design and post-processing stages This 3D data effectively captures not only the shape but also essential annotations, symbols, and dimensions relevant to design and manufacturing As multiple users reference this data, it is crucial for it to be easily transferable over networks, necessitating its lightweight nature Furthermore, an affordable viewer is sufficient for inspecting 3D shapes, while advanced viewers offer features for measuring dimensions and editing annotations.

Figure 2.4 illustrates the differences between 3D CAD and a viewer utilizing lightweight 3D data While design departments require CAD for creating, editing, or modifying 3D data, other departments that solely need to display 3D data can greatly benefit from lightweight formats This approach offers three significant advantages for non-design departments.

3 Data can be exchanged via network

Downstream departments such as production technology departments, facto- ries, quality assurance departments, service maintenance departments, and market- ing departments just need to display lightweight 3D data So, creating an environ-

Figure 2.4 Departments suitable for using “lightweight 3D data + viewer”

16 2 Trend Toward Use of Lightweight 3D Data ment that allows these departments to access and view 3D data is all that is needed to start using 3D data throughout the enterprise

Lightweight 3D data has numerous applications across various departments within companies Planning departments leverage 3D data for product planning, while design teams utilize it for comprehensive reviews of digital models Production technology teams implement XVL data in measurement verification systems to identify discrepancies between CAD designs and actual components On the factory floor, XVL enhances electronic reports, including parts lists and work specifications, significantly reducing the time required to generate these documents Additionally, the 3D format improves comprehension of reports for stakeholders Furthermore, 3D data proves beneficial for creating parts catalogs in service maintenance and web catalogs in sales departments.

Use of Lightweight 3D Data Throughout the Company

As XVL is adopted across multiple departments, many companies will encounter challenges related to data access, particularly when general users struggle to locate specific 3D data storage.

Figure 2.5 Areas of applying lightweight 3D data

To effectively utilize lightweight 3D data across the company, it is essential to establish clear guidelines for accessing the most up-to-date 3D resources A practical approach involves managing XVL within the company’s standard database, ensuring that all departments can seamlessly access and use this data.

Many companies utilize multiple 3D CAD systems and convert their 3D data into XVL format for cross-departmental accessibility This conversion significantly improves operational efficiency in areas such as design review, documentation, illustration, and the sharing of design and manufacturing information among various departments, including planning, manufacturing, production technology, and quality control While data sharing may pose security concerns, effective security control mechanisms for lightweight 3D data are already in place and will be addressed in a subsequent chapter.

Lightweight 3D data has gained significant importance in manufacturing departments, traditionally aligned with design teams Design departments utilize CAD to define product shapes, storing this data as official CAD models, which replace conventional drawings These models are updated as necessary, serving as master data Meanwhile, XVL is becoming the master data for manufacturing processes, increasingly incorporating essential information such as manufacturing instructions and dimensions within the XVL model This trend enhances the efficiency and effectiveness of manufacturing processes through the integration of 3D data.

Figure 2.6 Overall optimization effects of XVL as corporate standard data

18 2 Trend Toward Use of Lightweight 3D Data

Figure 2.8 Changes in work before and after implementation of XVL

2.3 Use of Lightweight 3D Data Throughout the Company 19

Historically, manufacturing instructions and attribute information were recorded separately by various departments on paper drawings, leading to a disorganized accumulation of knowledge Transitioning to lightweight 3D data allows for the digital integration of manufacturing data, resulting in several advantages These include the consolidation of manufacturing knowledge in XVL, improved feedback of manufacturing information to the design team, and centralized management of information previously spread across multiple drawings.

The system enables universal access to essential data, facilitating design reviews, verifications, and documentation Consequently, IT can enhance efficiency, allowing departments beyond manufacturing to reap the benefits of 3D design.

Lightweight 3D Data to Company-wide Use

Lightweight 3D data is useful throughout design and manufacturing Of course it also benefits local applications However, it is always important consider overall optimization when promoting 3D data

Since 2003, SONY has effectively integrated XVL technology into their trial production processes, learning the challenges of utilizing 3D data They recognized the difficulties faced by downstream teams in accessing and identifying the correct 3D CAD data To address these issues, SONY developed a comprehensive 3D data information distribution system, enabling seamless exchange of XVL data among all employees This robust infrastructure allowed any department to access 3D data as needed Additionally, SONY initiated projects to promote the use of 3D data, significantly enhancing employee awareness of its benefits.

SONY GLOBAL SOLUTIONS (SGS) spearheaded significant initiatives to establish the IT infrastructure for the entire SONY group Key leaders in this effort included Mr Watanabe, head of the Engineering Solution Division, and Mr Sekiya, head of the Engineering Information Solutions Division, while Mr Yoshii was responsible for constructing the actual infrastructure.

Mr Tsukamoto played a key role in the introduction and promotion of XVL, highlighting how SONY, a leading Japanese company, began utilizing 3D data Their experience in developing a robust 3D data distribution infrastructure offers valuable insights for organizations aiming to implement 3D data on a company-wide scale.

Use of 3D Data in Design and Manufacturing at SONY

Sony is a leading manufacturer known for its diverse range of digital equipment, including TVs, VCRs, camcorders, digital cameras, and PCs The company utilizes advanced technologies such as mechanical CAD, electrical CAD, and PDM/CAE systems to design, manufacture, and sell high-tech devices, ensuring innovation and quality in its products.

Sony is focused on expanding the use of lightweight 3D data across the company, led by Mr Watanabe’s Engineering Solution Division and Mr Sekiya’s Engineering Information Solutions Division These divisions advocate for the integration of IT in designing digital equipment, aiming to restructure the design processes for machines, electrical components, and embedded software Their approach emphasizes the adoption of cutting-edge design technologies and the establishment of a robust information infrastructure to support these advancements.

Since the 1980s, SONY has integrated CAD into its digital equipment design process, evolving its engineering management style from centralization to distribution and back to centralization in response to IT trends The 1980s marked a period of centralized management, transitioning to a decentralized approach in the 1990s with the adoption of PCs, which, while reducing costs, introduced trade-offs in Total Cost of Ownership (TCO) In the latter half of the 1990s, SONY shifted back to central management to achieve global optimization in a networked environment, implementing PC-based 3D CAD and extensive in-house CAE analyses This transition empowered designers to promote digital manufacturing using 3D data SONY's Product Lifecycle Management (PLM) system aims to enhance product release speed and foster unique product designs, requiring accessible product-related information across the company Rather than functioning solely as a CAD tool, this design platform serves as a comprehensive design system that incorporates valuable design know-how, facilitating the effective use of 3D data throughout the organization.

Figure 3.1 Transition of 3D CAD/CAE solution

At SONY, the integration of 3D data in design and manufacturing is crucial for optimizing product development Establishing a robust design information infrastructure ensures consistent 3D data usage, facilitating collaboration and efficiency across both internal teams and partner companies This approach enhances the horizontal distribution of design and manufacturing functions, driving innovation and productivity in the product design process.

Figure 3.3 illustrates SONY's optimal utilization of 3D data throughout various stages, including planning, design, prototyping, mass production, and service support This approach allows for seamless collaboration with mold subcontractors Consequently, all CAD data is transformed into lightweight XVL format and disseminated via a company-wide information distribution platform, ensuring that even data still in the design phase is accessible for effective communication and decision-making.

Figure 3.2 Core of PLM supporting SONY’s product design

Figure 3.3 Best practice of lightweight 3D data

Sony is exploring the expansion of lightweight 3D data across the company by converting it to XVL format for accessibility Prior to this implementation, Sony conducted multiple evaluations of XVL, assessing its practical benefits in real work scenarios This thorough examination led to the decision to adopt XVL as a valuable tool for the organization.

Introduction of Lightweight XVL 3D Data

Before SONY adopted XVL, their design data flow primarily relied on traditional drawings even as they began integrating 3D elements into their design process After the prototyping phase, the company continued to use these drawings to ensure that the final product matched the initial designs, emphasizing a focus on the downstream production process.

Identifying issues in the upstream process is crucial for enhancing design work, as demonstrated by SONY's 2002 technical evaluation of lightweight 3D data They chose to implement XVL due to its high accuracy, lightweight nature, web distribution capabilities, cost-effectiveness, and reliability Starting in 2003, SONY began offering services to convert CAD files to XVL The automatic processing conversion mechanism they developed enabled successful prototyping projects, confirming that XVL significantly improves operational efficiency.

Figure 3.4 Initial design and manufacturing data flow

Construction of “3D Data Information Distribution Platform”

Data Sharing

Authorized personnel can access XVL data at any time, specifically those involved in manufacturing and quality assurance The system automatically converts approved 3D CAD data to XVL, enabling access even during the design phase This capability allows designers to verify their work early on and enables the production technology department to begin preparations ahead of schedule.

Data Distribution and Management

Notifications for 3D data distribution are sent to users needing it for applications like prototyping and manual preparation, facilitating easy access to essential data Available in various formats, including CAD, XVL, and IGES, lightweight XVL is commonly utilized in downstream processes Manuals are created concurrently with design, streamlining the workflow Previously, users had to request data individually and convert it to XVL, but the new distribution system significantly minimizes unnecessary tasks and reduces distribution errors.

Management of Original Drawing Data

The final design-approved data is securely stored and accessible through the 3D data distribution system, featuring drawings in PDF format and 3D data in XVL These formats facilitate easy referencing from company-wide common parts lists, ensuring consistency Verification processes can confirm the legitimacy of this final data, providing clarity on which lightweight XVL data is definitive from a downstream perspective.

Users can easily access the latest design data by obtaining approval for the design side As long as the 3D data is shareable, XVL can be accessed from any manufacturing site globally.

Business Process Restructuring Using Lightweight 3D Data

Authorized personnel can access XVL data anytime, with access limited to those involved in manufacturing and quality assurance When an approved request is made, the system automatically converts 3D CAD data to XVL format This capability enables designers to verify their work and collaborate with others early in the design process, while also allowing the production technology department to begin preparations sooner.

Notifications for 3D data distribution are sent to users needing access for purposes like prototyping and manual preparation This streamlined process allows easy access to necessary data in various formats, including CAD, XVL, and IGES The lightweight XVL format is commonly utilized in downstream processes, while manuals are developed concurrently with the design Previously, users had to request data individually and convert it to XVL, but the new distribution system significantly minimizes unnecessary work and reduces distribution errors.

3.3.3 Management of Original Drawing Data

The finalized design data is securely stored and accessible through the 3D data distribution system, featuring drawings in PDF format and 3D data in XVL These formats facilitate easy referencing from the company's common parts lists Additionally, verifications can be conducted to ensure the legitimacy of this final data, providing clarity on which lightweight XVL data is definitive from a downstream perspective.

Users seeking design data can easily access the latest information by obtaining approval for the design section With shareable 3D data, XVL can be accessed from any manufacturing location worldwide.

3.4 Business Process Restructuring Using Lightweight 3D Data

Since 2003, SONY has actively utilized 3D data in its business operations, enhancing product understanding through animated reviews of XVL This approach not only clarifies product functions and structures but also fosters collaborative design discussions among manufacturing and service departments.

28 3 SONY’s Ideas on Expanding Lightweight 3D Data to Company-wide Use activities gradually revealed the merits of XVL, such as easy to understand struc- ture and functions

At SONY, enhanced comprehension of shapes during design meetings led to more enthusiastic discussions about improvements and a reduction in downstream process steps Additionally, SONY experimented with XVL for crafting manufacturing instructions, resulting in a significant decrease in the time required to create actual object drawings, reducing it from one week to just one day.

The company’s next task was to expand the use of XVL throughout the organiza- tion SONY therefore launched a project leverage 3D throughout the company In

In 2004, SONY's design working group convened to explore effective applications of 3D data across various products, involving representatives from multiple departments to facilitate the sharing of successful strategies This collaborative approach enabled the implementation of a standardized Bill Of Materials (BOM) system, enhancing the ability to replicate successes across different sectors within the company To assess the applicability of 3D data in specific company activities, target areas for XVL use were meticulously evaluated The introduction of new business processes often hinges on individual motivation; without staff enthusiasm and recognition of the benefits, adoption can be challenging The SONY working group's initiatives played a crucial role in driving motivation and fostering the acceptance of innovative practices within the organization.

SGS aims to develop a mechanism that streamlines the integration of new technologies in manufacturing through IT For instance, during design reviews utilizing 3D data, it can be challenging to involve experienced personnel from the manufacturing department, often leading to younger engineers participating for training purposes Engaging in detailed discussions about 3D technology with seasoned designers may prove to be a complex task.

XVL enables pre-verification of data on-site and facilitates prior study before design staff meetings, a process supported by the SONY working group Over time, these design review meetings became increasingly dynamic, introducing innovative methods for utilizing 3D data within SONY The introduction of a new 3D information distribution system allowed SONY to extend the application of 3D data across its global operations Previously, requesting XVL conversion from CAD data was challenging for manufacturing engineers who did not know the designer; however, the new mechanism now permits anyone to access XVL, overcoming language barriers and geographical distances Additionally, engineers worldwide can conduct design review meetings via telephone conferencing, enhancing collaboration and accessibility.

During the SONY working group meetings, two key advantages of utilizing 3D technology were highlighted: prototype review and work standards In prototype reviews, product structures are thoroughly analyzed in 3D prior to meetings, enabling team members to better understand designs, especially those who struggle to visualize shapes from traditional 2D representations.

Business process restructuring through the use of lightweight 3D data enhances participant engagement in meetings, leading to the early identification and resolution of issues This proactive approach results in improved design quality and reduced development timelines.

In the past, SONY relied on borrowing prototypes and photographing them to create work standards, but this method limited their ability to edit the images The introduction of XVL technology has revolutionized their process, enabling data editing and allowing for data reuse even when assembly procedures change As a result, SONY achieved a remarkable 30% reduction in drawing time.

Figure 3.8 XVL utilization zone map

30 3 SONY’s Ideas on Expanding Lightweight 3D Data to Company-wide Use

Historically, manuals were created primarily in downstream processes, with detailed preparation commencing only after prototype completion However, the integration of 3D data has facilitated earlier manual preparation, leveling the workflow Highlighting and sharing these benefits within the SONY working group is crucial, as it fosters momentum for broader implementation across the company and establishes a platform for the distribution of 3D data.

Future Plans

SGS has successfully developed a 3D data information distribution platform, transforming design business processes across the SONY Group and establishing best practice scenarios for 3D usage This 3D infrastructure allows users to easily access essential 3D data.

Departments across the company are achieving significant improvements through proactive initiatives, such as transforming past models into accessible 3D data for the manufacturing team This practice is becoming commonplace, with the use of 3D data increasingly integrated into downstream processes Looking ahead, SONY recognizes the need to enhance lightweight 3D data by incorporating essential information like part numbers, model names, and other product specifications to maximize its effectiveness.

Figure 3.9 Advantages of using XVL in prototype review

Sony aims to create digital models that simulate product behavior while transitioning from object-centric rules to those focused on information, data, and software They envision 3D models functioning like actual products based on user instructions, facilitating the verification of functionality and usability Once these digital models are developed to uniformly handle product mechanisms and the software driving them, they will enable operational verification on PCs and serve as tools for early-stage marketing prior to product release.

With their 3D data distribution infrastructure and experience in data use, SONY is steadily working on their next challenge

Figure 3.10 Advancement of CAD use

Between 1996 and 2000, the US GDP experienced a growth of 4–5%, with IT contributing 1.4%, while the US manufacturing industry saw productivity per person increase over tenfold in the past decade In stark contrast, Japan's GDP growth during its "lost decade" was only 1%, highlighting the need for Japanese industries to adopt IT more effectively In response, the Japanese manufacturing sector has begun leveraging lightweight 3D data to improve business efficiency, particularly in automotive, electrical equipment, and precision machinery sectors This technology aids in various routine tasks such as preparing work instructions, facilitating communication between designers and engineers, verifying design concepts, and sharing information with suppliers and customers This chapter explores the advantages of lightweight 3D data across different industrial applications and contrasts traditional manufacturing methods with those utilizing lightweight 3D data, like XVL.

Table 4.1 Examples of user applications of XVL

Company Outline of user applications

NIKON utilizes XVL technology for design reviews of extensive 3D models in car body design, significantly reducing costs through the automatic interference check function that identifies and addresses issues early in the process Additionally, the company improves design quality by conducting comprehensive reviews of challenges during design review meetings.

Toyota leverages 3D CAD technology to design semiconductor manufacturing machines that comprise hundreds of thousands of components By utilizing XVL for product development meetings and manual preparation, the company is significantly enhancing work efficiency Presently, XVL serves as the fundamental tool for communication within Toyota.

Company Outline of user applications

YAMAGATA CASIO has boosted production efficiency by 30% by integrating XVL into its manufacturing and assembly processes, enhancing die and mold management through improved process specifications This incorporation of XVL has facilitated a 3D drawing-less culture by embedding critical information like tolerances and finished states Similarly, ALPINE PRECISION has replaced traditional reports and drawings in die and mold making with XVL, significantly improving information sharing between design and manufacturing teams This early-stage preparation for manufacturing has led to better die and mold quality, while also allowing for feedback that enhances design quality Additionally, ALPINE PRECISION utilizes XVL for effective information exchange with its overseas operations.

TOKAI RIKA has enhanced manufacturing efficiency by utilizing XVL to visualize die production information, allowing experienced engineers to create specifications based on 3D data This approach enables production, inspection, and manufacturing departments without CAD systems to offer design feedback effectively Similarly, CASIO has implemented a system that compiles instruction manuals and parts catalogs using 3D data, predominantly leveraging XVL for most of its products By developing a web-based system that allows users to convert 3D data to XVL on demand, CASIO efficiently integrates 3D data into its downstream processes.

By standardizing the use of 3D data across all suppliers and partner companies, the company has significantly lowered costs Additionally, they offer customers 3D process animations for product assembly, which can also be utilized for product maintenance.

KVAL (USA) has significantly enhanced maintenance efficiency through the management of customized product information with XVL Additionally, the company has streamlined the technical training process for new engineers by effectively utilizing 3D data.

MAN in Germany has integrated XVL into its comprehensive product data management system, significantly enhancing internal communication Additionally, the company has deployed XVL Player across numerous PCs, facilitating efficient 3D information transfer.

Use of XVL in Design Review

Professor Takahiro Fujimoto from the University of Tokyo identifies two primary types of manufacturing industries: combination (modular) manufacturing and collaborative (integral) manufacturing Combination manufacturing involves assembling pre-designed parts, where each component performs a specific function, exemplified by products like personal computers In contrast, collaborative manufacturing requires a more integrated approach, where components work together more holistically to create the final product.

The use of XVL in design review is essential for optimizing the component parts of a product in collaborative manufacturing, particularly in the Japanese automotive industry Effective communication between designers and engineers is crucial for integrating and optimizing diverse parts, making Design Review (DR) a vital process Without DR, designers may lack a comprehensive understanding of the overall system, leading to design errors that can result in costly changes and significant delays, especially if modifications are needed after production has started.

During Design Reviews (DRs), stakeholders from various stages of the manufacturing process convene to analyze 3D data, identifying design errors and assessing the feasibility of the assembly process while addressing potential manufacturing issues Feedback from these discussions is relayed to the design department to enhance design quality early in the development stage, thereby predicting and preventing downstream problems The integration of lightweight 3D data significantly boosts DR efficiency, facilitating the handling of large data volumes and enabling seamless data sharing across networks Moreover, the mandatory use of 3D data in DRs ensures thorough detection and resolution of design quality issues, ultimately reducing the occurrence of problems in later manufacturing stages.

In collaborative manufacturing companies, the substantial volume of 3D CAD data complicates data review during design reviews (DRs), as larger 3D models result in slower viewer responses The sheer size of current models makes it impractical to display all data within a single CAD session, leading to the reliance on traditional methods that utilize 2D drawings and cross-sections for effective communication and analysis.

Figure 4.1 Types of manufacturing industry

Lightweight 3D data offers significant advantages, particularly in enhancing collaboration among designers and engineers These digital resources, when prepared in advance, streamline the design process and save valuable time Moreover, they enable participation from team members who may lack drawing literacy, ensuring that everyone can contribute effectively to project development.

Figure 4.4 illustrates the advantages of using Design Rules (DRs) with XVL technology Previously, checking for part interference in CAD required the removal of non-essential components from the data to create 2D images and cross-sections This manual process often necessitated visual inspections of the cross-sections, leading to potential oversights in identifying interference issues and resulting in additional complications.

Figure 4.2 Effects of design review

Figure 4.3 Conventional design review methods

4.1 Use of XVL in Design Review 37 man-hours XVL resolves all of these problems by automatically detecting all interferences on the complete model

XVL enhances the design process by performing automatic clearance checks, identifying areas that fall below necessary clearance values to prevent defects It efficiently calculates interference in large models without the need for data subdivision, and can also assess interference by offsetting surface data, making it particularly effective for evaluating car body surfaces This capability significantly reduces the time required for checks while improving accuracy in interference and clearance assessments.

By pinpointing problems in the design stage, XVL makes it possible to resolve them before they move downstream

Figure 4.5 Benefits of design review with XVL studio (2)

Figure 4.4 Benefits of design review with XVL studio (1)

Creating parts lists is a standard practice in the manufacturing industry for effective parts information management These lists include essential details such as structural information, delivery times, product specifications, suppliers, and quantities Typically, parts lists are compiled by summarizing attributes using word processors or spreadsheets As illustrated in Figure 4.6, they are often printed on paper, accompanied by notes and hand drawings, and shared with relevant stakeholders.

The integration of lightweight 3D data revolutionizes the management of parts information As illustrated in Figure 4.7, 3D shape data can be seamlessly linked to parts information and shared across networks Figure 4.8 demonstrates an automated approach for generating 3D parts lists Utilizing XVL tools, parts information in Comma Separated Value (CSV) format can be combined with XVL 3D shape data, resulting in a comprehensive 3D parts list ready for network sharing.

The advantages of 3D parts lists are significant, as they enable automatic generation, which removes the necessity for manual illustrations and reduces the risk of matching errors between parts and their data Additionally, 3D parts lists can incorporate attribute data and be printed on paper, providing versatility They also allow for easy updates to reflect design changes, ensuring accuracy and efficiency in the documentation process.

Many companies utilize XVL technology to develop extensive libraries of 3D parts, allowing users to search for shapes by manufacturer or part name By examining these shapes through 3D data, they can efficiently identify standard parts, despite the commonality in their designs.

Figure 4.6 Distribution of parts information using paper

Identifying the correct part using only 2D images can be challenging; however, 3D XVL technology significantly enhances part identification accuracy Previously, building and maintaining parts libraries was costly, but the method illustrated in Figure 4.8 allows for the automatic creation of 3D parts libraries, streamlining the process and reducing expenses.

Figure 4.7 Example of 3D parts list using XVL

Figure 4.8 3D Parts list after XVL implementation

Many companies utilize parts catalogs to deliver essential information for maintenance and procurement These catalogs typically detail the structure, shape, and attributes of various parts Traditionally, parts catalogs were created in paper format, as illustrated in Figure 4.10.

Figure 4.10 Problems in conventional preparation of catalogs

Figure 4.9 Benefits of 3D parts lists

Creating 3D parts catalogs is a labor-intensive process that involves translating and reformatting materials for global distribution, particularly for overseas partners Each time design changes occur, these catalogs must be redone, leading to increased costs Traditional methods of preparing illustrations often require illustrators to manually visualize and draw 3D shapes from surface drawings using illustration software Given that parts catalogs can feature dozens to thousands of components, this manual approach demands significant time and effort.

In the manufacturing industry, traditional methods of creating 3D illustrations, such as disassembling objects using CAD or photographing actual items, present significant challenges While CAD allows for the generation of image data without relying solely on surface visuals, it becomes impractical when dealing with numerous parts Additionally, photographing and illustrating large objects, like cars or cranes, can be time-consuming and may not always be feasible, as disassembly can take weeks or the actual object may not be accessible Consequently, these conventional approaches highlight various limitations in the collaborative manufacturing process.

Animated 3D Visual Manuals

Traditionally, illustration preparation began only after product completion, leading to high costs, tight deadlines, and inconsistent quality However, these issues can be addressed by generating lightweight 3D data right after the design phase, allowing for the automatic creation of high-quality illustrations.

Creating illustrations from 3D data eliminates the need to produce them manu- ally It allows the illustrations to be started immediately after design completion

Automated PC-generated illustrations ensure consistent quality across various designers while reducing costs As demonstrated in Figure 4.14, optimizing the documentation process can lead to significant enhancements in quality, delivery time, and overall cost-efficiency.

The shift from 2D illustrations to 3D animations in manuals is becoming increasingly prevalent due to the enhanced clarity they provide As the manufacturing workforce ages and globalization expands, effectively transferring knowledge to new employees presents significant challenges 3D animations simplify complex concepts, making it easier for newcomers to grasp essential manufacturing processes.

Figure 4.14 Comparison of documentation processes

Lightweight 3D data offers significant advantages, particularly in creating animated 3D visual manuals that provide universal, easy-to-follow instructions These manuals, as illustrated in Figure 4.15, showcase animated work procedures and serve as effective assembly and maintenance guides The use of 3D animations enhances comprehension and efficiency in various tasks.

Figure 4.15 Examples of visual manuals using XVL

Figure 4.16 Conventional preparation of work procedures

Conventional non-3D manuals are created by authors who gather necessary materials, including scanning technical specifications, work drawings, and taking digital photographs, along with hand-drawn illustrations They compile the manual and write instructions using a word processor, often lacking access to 3D CAD systems These manuals, primarily used by experienced instructors to train new workers, face significant challenges as Japanese firms expand into foreign markets, where the absence of guidance for overseas employees becomes a pressing issue Additionally, paper manuals that rely solely on text and images can be unclear and non-intuitive for newcomers.

Visual manuals utilizing XVL technology offer significant advantages by allowing authors to leverage 3D data, thus removing the need for traditional illustrations or photographs These 3D manuals enhance user engagement by enabling zooming into specific areas, viewing hidden components from various angles, and accessing critical animations, which leads to a deeper understanding of the material Their intuitive design empowers employees to self-learn effectively Additionally, as long as the 3D data remains lightweight, these manuals can be easily distributed online, making them ideal for training in fast-paced environments where assembly training is needed even before product availability Ultimately, 3D manuals reduce instruction time while improving comprehension and retention among trainees.

While 3D manuals offer numerous advantages, creating them used to be time-consuming However, advancements in animation software, such as XVL, have streamlined this process significantly With XVL, users simply input the assembly order, and the software automatically generates the necessary animations This innovation allows for quick and easy creation of 3D manuals, with the option to make further adjustments if desired.

Figure 4.17 Problems of conventional methods

Sharing CAE Analysis Results

Many companies leverage Computer-Aided Engineering (CAE) tools throughout the design process to simulate various forces, including stress and temperature, on models without the need for physical prototypes While recent advancements have made some CAE systems user-friendly for designers, most organizations still prefer to employ specialized analysts to evaluate the 3D models created by their design teams.

Figure 4.19 Example of CAE data converted to XVL

Figure 4.18 Benefits of visual manuals using XVL

Sharing CAT Measurement Data

CAE systems are typically more complex and expensive than CAD systems, generating large volumes of data that require costly analysis software for visualization Analysts commonly create reports by incorporating 2D images from the analysis, while much of the data is overlooked If designers wish to examine specific details or alter their perspective, they must reanalyze and recalculate the data.

Converting analysis data to XVL format allows for the visualization of results through color contour maps, highlighting areas of high stress in red for easy identification This method compresses gigabytes of data into a few hundred kilobytes, facilitating efficient sharing Additionally, XVL supports 3D annotations and hyperlinks, enhancing the dissemination of design knowledge across the organization By making these analysis results accessible company-wide, young designers can learn from past design issues, fostering a culture of collective learning and improvement.

Manufactured products do not always perfectly align with their 3D CAD models due to the limitations of manufacturing processes For instance, sheet metal can bend under the influence of gravity, even when machined with precision Designers must account for both the precision of parts and environmental factors when creating their models to ensure better alignment with the final product.

Figure 4.20 Example of CAE data converted to XVL

Lightweight 3D data offers significant advantages, particularly in ensuring manufacturing accuracy By utilizing a Computer-Aided Testing (CAT) system, the final product can be effectively compared to the original 3D CAD models This process ensures that the product meets the specified dimensions, enhancing quality control and precision in manufacturing.

A CAT system utilizes point capture devices to measure physical products, which can be categorized into two types: contact devices that physically touch the object and non-contact devices that employ lasers for measurement Recently, non-contact devices have gained popularity due to their ability to measure large volumes efficiently.

Figure 4.21 Example of CAT data converted to XVL

Figure 4.22 Benefits of sharing CAT analysis results

Collaborative Design Using Lightweight 3D Data

Advancements in data measurement enable the creation of extensive 3D point clouds that can now be efficiently analyzed using XVL, eliminating the need for costly analysis systems This process allows for the generation of color contour maps that visually represent discrepancies between the 3D model and the actual product As illustrated in Figure 4.21, the color variations highlight areas where the final product deviates from the original CAD specifications, facilitating effective communication of results across the organization.

This method enhances manufacturing accuracy across all plants, including those overseas, by allowing the production process for a part to be developed at one facility and then replicated at others, ensuring consistent quality An XVL-based CAT system plays a crucial role in maintaining high manufacturing standards by relaying issues back to the design team, enabling continuous improvement in design quality This process relies on the use of lightweight 3D data for effective implementation.

4.7 Collaborative Design Using Lightweight 3D Data

Lightweight data uniquely utilizes 3D data for streamlined communication across design departments and partner companies This innovative approach enhances collaboration and efficiency, as illustrated in Figure 4.23.

Lightweight 3D data exchange significantly enhances collaboration between designers and engineers by streamlining communication Traditionally, designers would send 2D drawings to engineers, who would create 3D CAD models and return them for feedback This process was often time-consuming and inefficient By utilizing lightweight 3D data, teams can share detailed models instantly, facilitating quicker discussions and decision-making This innovative approach not only saves time but also improves accuracy and fosters a more dynamic workflow in design and engineering projects.

XVL enables designers to efficiently share lightweight 3D models with engineers for visual review, significantly reducing the need for frequent meetings By sending XVL models immediately after completing the initial design, communication between designers and engineers is greatly improved A key advantage of XVL is its compatibility with standard PCs, allowing designers to present design concepts without needing to be in the CAD room Instead, they can showcase 3D animations in any meeting room using a notebook PC, engaging various stakeholders, including design, engineering, manufacturing, sales, marketing, and maintenance teams.

3D animation enables individuals who struggle to visualize designs from traditional drawings to grasp the true essence of a product This technology not only enhances internal understanding but also serves as a powerful tool for external presentations and effectively communicates marketing strategies to clients.

The straightforward nature of the data allows clients to quickly determine their interest in the product, resulting in higher marketing quality compared to verbal descriptions of the product image.

Lightweight 3D data is essential for effective communication between suppliers and mold manufacturers, especially when they use different CAD systems Since mold manufacturers often work with multiple clients, maintaining various CAD systems is impractical XVL addresses this challenge by enabling the sharing of simple shapes between the parties involved Both the mold manufacturer and the outsourcer can convert their data to XVL format, facilitating easy email exchanges This allows each party to review, annotate, and return the data, streamlining processes such as verifying parting lines on the model.

This chapter explores various applications of lightweight 3D data, ranging from simple 3D shape verification to enhancing communication through the integration of 3D and manufacturing attribute data, as well as the addition of animation A notable example is the sharing of CAE and CAT data, already adopted by many companies Subsequent chapters will present case studies from Japan, the USA, and Germany, highlighting how these companies utilize XVL, the challenges they face, and the contexts in which they apply 3D data.

Design Review in Body Design: Case Study of TOYOTA MOTOR CORPORATION

Eighty percent of a product's production costs are determined during the design stage, making it crucial to prioritize high-quality design from the outset At Toyota Motor Corporation, the quality of body design is improved through design reviews (DR) utilizing XVL technology This chapter highlights the practical applications of 3D data in the design review process, as outlined by Mr Junichi Harada, general manager of the body and electronic parts design division at the Lexus Center.

Mr Harada expresses his concerns about over-reliance on 3D technology, emphasizing the importance of cautious usage However, he acknowledges that he has experienced significant advantages in the realm of Digital Rendering (DR) through the application of 3D This insight was shared during his keynote speech at the XVL Solution World event on May 11, 2006.

Why is Design Review Necessary?

To meet consumer demand swiftly, automotive manufacturers are increasingly updating their models, leading to significant changes in the body development process Many companies are transitioning from progressive development, which begins production preparations post-design completion, to concurrent development, where design and production planning occur simultaneously This approach, referred to as simultaneous engineering by TOYOTA, enhances efficiency and responsiveness in the automotive industry.

Simultaneous engineering is a collaborative approach where initial design development occurs alongside production preparation, allowing for real-time refinements Designers create a design that aligns with set goals, making immediate adjustments when issues arise during the process Utilizing 3D CAD technology, these modifications are integrated into the CAD data daily This method ensures that drawings are finalized concurrently, enabling the timely commencement of die and mold production.

52 5 Design Review in Body Design: Case Study of TOYOTA MOTOR CORPORATION

In a simultaneous engineering environment, constant changes in both a designer's parts and neighboring components can lead to unintended interferences, particularly in the automobile industry, where products consist of thousands of parts These interferences, often caused by local design criteria adjustments, can escalate into significant downstream manufacturing issues, resulting in increased costs and delivery delays Early detection of these problems is crucial, and Design Review (DR) processes can help identify interferences before they become critical However, DR must be an ongoing practice, as resolving one issue may inadvertently create new ones As simultaneous engineering accelerates product development, proactive identification and resolution of design conflicts using 3D data become essential for success.

Design Review Using XVL

TOYOTA uses Lattice’s XVL Studio Pro in their DRs In the past, they carried out DR according to the following procedure:

1 Since CAD systems cannot display very large assemblies, remove all unneces- sary parts

2 Generate cross-sections of the reduced CAD assemblies

3 Visually check the cross-sections to find interferences

Figure 5.1 Conventional design methods are gradually changing to simultaneous engineering methods

Detecting interferences through cross-section analysis can be labor-intensive and prone to oversight, particularly during peak design periods This method places a significant burden on designers, who must manually review numerous cross-sections, increasing the risk of missing critical interferences or generating incorrect cross-sections XVL Studio Pro addresses these challenges by streamlining the design review process, enhancing efficiency and accuracy.

1 Display and process a complete automobile at one time on a PC (Figure 5.2)

2 Automatically calculate interferences between all parts, and display cross- sections of interferences in real-time (Figure 5.3)

3 Automatically generate reports of interference results including pictures and diagrams of the interferences (Figure 5.4)

At TOYOTA, DR reports serve as comprehensive management tools that ensure all issues are thoroughly investigated and resolved These reports include a check column for quick visibility of problem status There are two types of DRs conducted: during the design stage and after final design revisions The initial DRs aim to prevent issues from escalating beyond the design phase As new challenges arise daily in the simultaneous engineering process, repeated DRs effectively address these problems before they intensify, leading to continuous problem discovery and resolution with each iteration.

The final design review (DR) is conducted after the completion of the final drawings and serves as a crucial design validation step performed by an independent third party At this stage, all issues must be addressed and resolved XVL Studio Pro streamlines the final DR process, significantly reducing the time needed and alleviating the workload on designers, allowing them to concentrate on essential and innovative design tasks.

Figure 5.2 Example displaying mass data on PC

54 5 Design Review in Body Design: Case Study of TOYOTA MOTOR CORPORATION

Figure 5.3 Real-time display of cross-section of interference

Figure 5.4 Interference results report preparation function, can enlarge and display interference

The Actual Design Review Process

5.3 The Actual Design Review Process

Introducing new business processes and tools in busy design environments can be challenging, as they must offer clear benefits without adding to the designers' workload A practical approach to implementing lightweight Design Review (DR) is to establish a DR Preparations Team responsible for gathering necessary 3D data and converting it to XVL format By demonstrating the capabilities of XVL Studio Pro at the DR site, designers can directly experience how it helps identify interference issues that might otherwise go unnoticed Once they recognize the advantages, designers are more likely to adopt lightweight DR practices.

At TOYOTA, the Design Review (DR) process is conducted in two phases: sheet metal DR, which examines the interference between sheet metal components, and DR of all parts, focusing on the interference among all parts This intensive process involves scheduling detailed checks for each body part, with all relevant staff attending meetings Prior to these meetings, the DR Preparations Team utilizes XVL Studio Pro for automatic interference checks to identify issues During the meetings, staff collaboratively resolve problems in real-time As simultaneous engineering advances, interference challenges arise daily, but XVL Studio Pro efficiently conducts extensive checks on large assemblies and generates reports Issues are systematically managed and addressed in follow-up meetings, allowing designers and manufacturers to allocate more time to innovative tasks such as product development and manufacturing.

Figure 5.5 Repetition of DR decreases number of defects

56 5 Design Review in Body Design: Case Study of TOYOTA MOTOR CORPORATION

Applications and Development of Design Review

Designers are increasingly enthusiastic about XVL Studio Pro, recognizing its versatility beyond interference checking It facilitates various applications, including optimizing cable arrangements, enhancing assembly efficiency, ensuring clearance between movable parts, preventing abnormal sounds, and assessing product appearance XVL enables collaborative visual problem-solving, allowing teams to identify and address issues in real-time For instance, it effectively visualizes complex wire harness arrangements in instrument panels, overcoming limitations of traditional CAD systems that struggle with large-scale data While 3D visualization may not fully capture bent or twisted wire harness sections, XVL supports design reviews by comparing actual parts Additionally, it aids in resolving assembly and repair challenges by displaying related components, helping teams quickly identify and rectify issues through minor adjustments.

The use of XVL technology facilitates collaboration among related parties and enhances the visual inspection of large assemblies, leading to quicker problem resolution across different divisions Previously, even minor issues could take considerable time to address Additionally, XVL DR is applied in building construction and appearance reviews, helping designers verify if the construction aligns with their original vision The 3D visual display allows for immediate identification of discrepancies in parts assembly and positioning compared to the initial design plan.

XVL enhances appearance reviews by enabling 3D model visualization from all angles, surpassing the limitations of traditional 2D drawings This capability allows designers to effectively assess features, such as a lamp's appearance through a car's window, facilitating problem identification and resolution The versatility of XVL in design reviews (DRs) is evident as designers collaboratively explore new applications and targets While interference checking is a foundational aspect, the potential applications of 3D DR using XVL are boundless, driven by the creativity of the designers.

Advantages and Disadvantages of 3D Design

5.5 Advantages and Disadvantages of 3D Design

Mr Harada from TOYOTA emphasizes that the foundational aspects of design, including objectives, dimensions, and rationale, are determined by the designers themselves XVL serves as a tool to improve design completion, but the responsibility for refining the basic design lies with the designers Therefore, it is essential for designers to possess a strong understanding of fundamental design principles and manufacturing processes.

A recent trend among young engineers is the increasing reliance on 3D data, which simplifies the design process However, this has led to situations where the overall structure and design intent are unclear, as noted by Mr Harada He emphasizes that designers often depend on XVL for later reviews, neglecting the importance of expressing the core design through traditional drawings According to Mr Harada, 3D CAD shapes are merely representations of this core design concept While 3D shapes facilitate easy shape verification and communication among development teams, it is crucial for designers to articulate performance and functionality through drawings Design division supervisors play a vital role in instilling the core design principles and manufacturing spirit in young designers, which is a fundamental principle for Japanese manufacturers.

In the design process, leveraging both drawings and 3D data is essential for optimal results Conducting design reviews (DRs) based on traditional drawings allows for an assessment of the design's core elements, overall concept, and scale Meanwhile, DRs utilizing XVL technology offer benefits such as enhanced spatial effects, detailed verification of intricate components, and immediate identification of problem areas By strategically differentiating and integrating these methods based on specific requirements, designers can maximize the advantages of both approaches.

Figure 5.6 Heart of design, basics of design specified by drawings

In the case study of Toyota Motor Corporation, the design review process significantly enhances the quality and completeness of body design drawings This improvement in the design review methods leads to a higher degree of design completion, ensuring more refined and accurate outcomes in automotive design.

The "core of design" depicted in drawings is transformed into 3D shapes using CAD, which can then be converted into XVL for downstream processes and supplier use While 3D data is increasingly becoming the preferred method for conveying information, 2D drawings remain the authoritative source for the "core of design." Mr Harada emphasizes the importance for designers to clearly identify the core elements before starting the design of 3D shapes Ideally, the envisioned design concept should be accurately represented as 3D shapes in CAD.

Two Goals of Using XVL

The primary objectives of utilizing XVL are to minimize time spent on routine tasks like interference checking, allowing designers to focus on creativity, and to enhance design quality by integrating the benefits of both drawing-based and XVL-based design reviews This approach identifies issues early in the design phase, preventing them from escalating downstream, which in turn reduces costs and accelerates delivery However, the effectiveness of any tool hinges on its efficient use While simultaneous engineering can lead to increased interference and rework during design and manufacturing, the ultimate aim of design reviews is to eliminate unnecessary work, thereby improving quality and expediting delivery in concurrent development The significance of design reviews is growing in industries that rely on the integration of multiple components to achieve functionality and performance.

NIKON: Use of 3D Data as a Communication Pipeline

NIKON Precision Inc specializes in manufacturing semiconductor fabrication exposure devices (steppers) and LCD exposure devices, which are complex collaborative products The integration of 3D data significantly enhances design efficiency and improves downstream processes, despite the need for extensive trial and error XVL has become a vital communication tool within the NIKON group This chapter features an interview with Mr Kiyotaka Yamamoto, head of the precision machinery department, discussing their efforts to incorporate XVL into their design and manufacturing practices.

Environment of Semiconductor Fabrication Devices

The semiconductor fabrication device is essential for mass-producing semiconductors used in digital equipment, including automotive control systems, PCs, and smartphones This intricate machine comprises up to 100,000 components and typically requires over a year for product development As semiconductors become increasingly complex, the manufacturing systems must achieve high precision, necessitating the adoption of innovative technologies Additionally, intense competition within the industry is leading to shorter product cycles.

60 6 NIKON: Use of 3D Data as a Communication Pipeline

In a challenging environment, NIKON's development department faced significant obstacles that necessitated the division of design responsibilities among highly specialized engineers This specialization led to a focus on optimizing individual components, resulting in a scarcity of engineers capable of overseeing the entire development process Consequently, design reviews lacked depth and failed to provide a comprehensive understanding, making it difficult for NIKON to optimize designs holistically and effectively motivate their design engineers.

The company faced significant challenges due to the absence of CAD facilities in its downstream processes, which hindered the effective use of available 3D data As work was limited to traditional drawings, there was a pressing need to restructure business processes for greater efficiency The solution lies in innovating the design process through 3D design and integrating lightweight 3D XVL data into post-processing activities.

Design and Manufacturing Process Innovation with 3D Data

At NIKON, over 100 design department staff utilize 3D CAD for designing functional parts, streamlining the process of preparing tool sheets and assembly check sheets alongside design tasks Additionally, CAD data plays a crucial role in production and manufacturing applications, including shape verification and manual creation.

Figure 6.1 Semiconductor fabrication device and mechanism

NIKON leverages 3D data throughout its design and manufacturing processes, utilizing CAD for design tasks and seamlessly integrating this data into CAM applications in machining departments This innovative approach enhances efficiency and accuracy in production.

Lightweight XVL technology plays a crucial role in production management, particularly in downstream processes like logistics and development, as well as in creating presentation materials At NIKON, the design department was the first to implement 3D data, with 3D CAD introduced in 2003 to facilitate comprehensive product verification Additionally, 3D data has been utilized in meetings to inspire and motivate design engineers.

Semiconductor fabrication devices consist of 100,000 parts, necessitating collaboration among design engineers Traditionally, CAD systems limited designers to reviewing only their specific components, relying on 2D and full-scale drawings for design reviews However, the shift to utilizing 3D data for design reviews has eliminated the need for explanatory drawings, allowing for clearer communication of designs This transition to 3D design significantly enhances collaboration and motivation among team members, fostering a more efficient design process.

The adoption curve of 3D CAD in manufacturing, as illustrated in Figure 6.4, highlights the initial challenges of using this technology Initially, NIKON employed dedicated CAD operators rather than design engineers to manage 3D CAD systems However, as design engineers began to experience the benefits of 3D CAD through direct experience, they gradually started to adopt the technology themselves Within eighteen months, all design engineers at NIKON were proficient in using 3D CAD.

Figure 6.2 Use of 3D data in design and post-processes

62 6 NIKON: Use of 3D Data as a Communication Pipeline

Initially, PCs and projectors were allocated to the design department for viewing 3D data during meetings and design reviews Within six months, the integration of 3D data became standard in all design meetings, and within two years, its usage expanded company-wide.

Figure 6.3 Promotion of use of 3D data by department

Figure 6.4 Adoption of 3D CAD in the design department

6.4 XVL’s Role as a Communication Pipeline 63

Difficulties Using 3D Data in Downstream Processes

NIKON faced challenges in utilizing 3D data within its downstream processes, as the sharing of 3D data between manufacturing and design departments proved ineffective The company discovered that downstream staff were reluctant to use 3D CAD unless it was convenient, necessary, and clearly beneficial to their tasks.

Downstream departments, such as assembly and publications, faced challenges in promoting the use of 3D data due to a lack of common advantages across functions To address this, they introduced Design Reviews (DRs) based on 3D data, enabling the manufacturing department to request specific 3D CAD data from the design team However, manufacturing staff struggled with utilizing 3D CAD effectively and required a lightweight 3D solution NIKON selected XVL for its small data size, free viewer, and ease of conversion, but encountered significant delays due to the complexity of semiconductor fabrication devices, taking five days to convert 70 units with 70,000 parts manually To overcome this, they developed an automatic conversion system that integrates XVL conversion into their CAD data management, allowing for overnight processing of 70,000 parts This innovation enabled timely sharing of 3D data between the design and manufacturing departments as development progressed.

XVL’s Role as a Communication Pipeline

6.3 Difficulties Using 3D Data in Downstream Processes

NIKON faced challenges in utilizing 3D data within its downstream processes, particularly in the collaboration between manufacturing and design departments The company discovered that downstream staff were reluctant to adopt 3D CAD unless it was convenient and clearly demonstrated its value.

The downstream departments, such as assembly and publications, faced challenges in promoting the use of 3D data due to a lack of common advantages and understanding of how to implement it A breakthrough occurred when they introduced Design Reviews (DRs) based on 3D data, allowing the manufacturing department to request specific 3D data from the design team Manufacturing staff expressed a need for a lightweight 3D solution, leading NIKON to select XVL for its small data size, free viewer, and easy conversion capabilities However, they encountered significant delays, as manually converting 70 units with 70,000 parts took five days, hindering timely data supply to manufacturing To resolve this, they developed an automatic conversion system that integrates XVL conversion into their CAD data management system, enabling overnight conversion of 70,000 parts This innovation allowed the design department to share 3D data with manufacturing processes promptly as each development stage was completed.

6.4 XVL’s Role as a Communication Pipeline

At NIKON, XVL is revolutionizing communication by becoming an essential tool for meetings and documentation Initially, 3D data was utilized primarily for discussions, as seen in Figure 6.5, which showcases product improvement meetings using XVL data The integration of XVL simplifies downstream processes, making meetings more efficient Previously, the workflow involved converting drawings into 2D formats and photographing manufactured parts for documentation Now, with XVL, 3D models can be easily integrated into Microsoft Word and Excel, significantly reducing the time and effort needed for document preparation This advancement allows for the immediate creation of manuals once the design is finalized and 3D data is available.

64 6 NIKON: Use of 3D Data as a Communication Pipeline

NIKON has successfully leveraged 3D data to achieve a 30% reduction in costs and a 15% decrease in delivery times for manuals and reports The company utilizes XVL technology to enhance shape recognition in design data, cutting recognition time by 10% As a vital communication tool, XVL enables precise and efficient information sharing both internally and with other NIKON group and partner companies.

NIKON is making significant advancements by addressing the increased workload of design engineers due to the rise in 3D design adoption To reduce costs, they are replacing certain 2D drawings with 3D data.

Figure 6.5 Meetings using XVL for product improvement

Figure 6.6 Example of use of XVL in specifications and procedures to enhance communication efficiency

6.4 XVL’s Role as a Communication Pipeline 65

In the past, assembly drawings were created by combining component lists and multiple drawings, which often took one to two weeks for design engineers to finalize, even after completing the design with 3D data To enhance clarity in conveying information for large-scale products, the company improved the display and operational methods of the XVL viewer, facilitating easier verification of part positions This innovation allowed the company to replace traditional drawings with XVL, effectively communicating the positional information of parts.

Figure 6.8 Simplification of drawings using XVL

Figure 6.7 XVL is a MUST tool for efficient communication

66 6 NIKON: Use of 3D Data as a Communication Pipeline

Figure 6.9 illustrates the information flow in NIKON's design process, which utilizes CAD for design completion Once the design is finalized, component lists and CAD models are generated and must undergo a drawing registration process to integrate part data with models Using XVL technology, this data is automatically processed overnight, linking part data with the XVL model and distributing it to relevant departments.

Figure 6.9 Flow of design information from design to post-processes

Figure 6.10 Example of view model using XVL Web Master

Security: A Pending Task

The released view model depicted in Figure 6.10 was automatically created using XVL Web Master and one of its basic templates A key advantage of this template is the integration of the parts list with the shape, significantly minimizing the need for multiple assembly drawings.

NIKON aims to enhance the utilization of 3D data by addressing two key challenges associated with XVL: managing vast data volumes and ensuring data security Given the significant data requirements of semiconductor fabrication devices, it is essential to achieve high-speed display and illustration of large-scale data effectively.

Lattice's newly developed V-XVL technology (XV2) effectively addresses data display challenges by enabling the rapid visualization of large data sets while maintaining a minimal memory footprint.

The lightweight nature of XVL poses security risks, as it can be easily emailed and accessed by unauthorized individuals To address this issue, the company has implemented an XVL security system integrated with its internal authentication processes It is essential to establish such security measures before promoting the use of 3D data more widely.

In summary, the introduction of XVL at NIKON provided three main advan- tages:

1 Realization of front-loading by improving efficiency of design process and mo- tivating design staff, and promotion of communication between manufacturing staff and design engineers

2 Sharp reduction of time and costs for documentation by using 3D data

3 Easier and clearer communication between the design and manufacturing de- partments, partner companies, and suppliers

NIKON has discovered significant advantages in utilizing XVL as a communication tool, particularly in enhancing their handling of security issues By addressing these challenges, the company can further leverage the benefits of 3D data NIKON Precision Inc is consistently achieving success in the effective integration of 3D data within their downstream processes.

Practiced at Injection Mold Plant and Transfer of Technological Information

YAMAGATA CASIO, a manufacturing subsidiary of CASIO, specializes in assembling products and producing precise molds and molded parts The company has embraced 3D CAD/CAM technology early on to enhance data utilization and fully digitize its manufacturing processes By implementing XVL in production and assembly instructions, YAMAGATA CASIO has achieved a 30% increase in production efficiency and integrated XVL into its process management systems Insights from an interview with Mr Takaya, Deputy General Manager of the Engineering Department, highlight the company's innovative approach as of May 2006.

Digital Equipment Market

CASIO, known for its mobile phones and digital cameras, faces a short product lifespan of just four months for phones and six months for cameras due to rapidly changing consumer demands To adapt, CASIO and similar set manufacturers have streamlined their development processes YAMAGATA CASIO, a key partner, enhances production efficiency by implementing 3D CAD data and digital information distribution, significantly reducing preparation time Furthermore, YAMAGATA CASIO utilizes a networked system to automatically collect data and monitor machine tools and molding machines, ensuring a consistent supply of molded parts.

Figure 7.2 shows the transition in 3D design data The company introduced

2D CAD in 1988, and then CAM/CAE systems In the first half of the 1990s,

Figure 7.1 Market needs sought by digital equipment manufacturers and response

Figure 7.2 Conversion to 3D data and networking in design and manufacturing work at

In 2000, the company fully integrated 3D CAD/CAM systems within its design department, enhancing their design and manufacturing processes By 2002, they prioritized the utilization of 3D data, generating XVL viewer data and employing tools like "XVL Web Master" for parts management and "XVL Notebook" for documentation Additionally, they established a digital connection between CAD/CAM/CAE systems and various machine tools, including machining centers and electric discharge machines, as well as molding machines linked to auto stockers This networked system enabled real-time monitoring and immediate alerts to the responsible personnel via mobile notifications in case of processing issues.

The flow of digital data begins with the company receiving product data and specifications from customers Utilizing this information, the company models the product, designs the mold, and creates jigs (tools) through the Unigraphics 3D CAD system.

Based on customer requirements, prototypes are constructed using 3D technology, which provides valuable shape data for Computer-Aided Manufacturing (CAM) and Computer-Aided Engineering (CAE) This data is then converted to XVL for downstream processes, such as jig design, where XVL helps identify the most effective method for controlling the location of a workpiece in mass production.

Figure 7.3 3D digital data flow: XVL is used downstream

Why 3D Design Alone is not Effective

Design is the process of embodying and expressing one's vision, as explained by Mr Takaya A designer utilizes available knowledge to translate their ideas into specific procedures, starting with a clear conception of the desired outcome This involves selecting the shape and materials, determining the construction method, and articulating these elements through detailed drawings and specifications Drawings serve to communicate the designer's intent, encompassing various aspects such as shape, size, tolerances, joint states, critical dimensions, material quantities, machining processes, and the final product state Ultimately, these drawings are essential for conveying the comprehensive design intent.

3D CAD data only expresses shape, which means the effects of designing by

3D design has its limitations, as designers often struggle to accurately convey their intent without drawings Drawings remain crucial in the design process, even after 3D models are created Mr Takaya from YAMAGATA CASIO notes that they transitioned from 2D to CAD for 3D surface models and later to 3D solid models Despite this advancement, eliminating the use of drawings proved challenging However, with the evolution of XVL technology, they have successfully achieved complete utilization of 3D data.

XVL became available, and established a system for transferring the design intent to downstream processes without drawings

Figure 7.4 What is design? What are the roles of drawings?

Ideals of Design and Mold Fabrication

YAMAGATA CASIO previously relied on 3D data and 2D drawings to convey design intent, which was essential for their manufacturing processes However, they faced delays as the drawing phase could only commence after the completion of the 3D design, ultimately prolonging manufacturing time While the adoption of 3D design improved accuracy and quality, it became clear that to enhance the efficiency of downstream processes, the company needed to eliminate drawings altogether Simply introducing 3D design was insufficient to reduce overall lead time.

7.4 Ideals of Design and Mold Fabrication

The process from design to mold fabrication, as illustrated in Figure 7.6, emphasizes the importance of utilizing only 3D data throughout all manufacturing stages At YAMAGATA CASIO, manufacturing challenges can be effectively addressed through a process management system that eliminates the need for traditional drawings, allowing for centralized management of all molding information.

In the design process, attribute information that was once manually incorporated into drawings can now be efficiently inputted through a CAD system Custom programs are capable of extracting this attribute information and presenting it as a table in CSV format, streamlining data management and analysis.

Figure 7.5 Problems of conventional design methods

Yamagata Casio enables the integration and sharing of design and parts information through XVL, starting from the early stages of the design process This approach facilitates accurate tracking of schedule changes in downstream processes by providing real-time status updates.

The XVL Notebook is a powerful tool for generating processing instructions using 3D data, allowing manufacturers to access part attribute information directly from CAD files This integration of 3D data and attributes facilitates a visual inspection of the joint states of mold surfaces, which is crucial for mold making Additionally, the 3D visualization aids users in comprehending complex fittings that may not be easily interpreted from traditional drawings.

The XVL Web Master system facilitates the precise transfer of information to external processors, enabling the generation of detailed assembly instructions that verify part positions and streamline the assembly process.

This system helped YAMAGATA CASIO shorten production lead time by

30%, something which was not possible with 3D designs alone.

Introduction of Process Management System

Another important endeavor was the company’s introduction of a process man- agement system (Figure 7.7) This system transfers design information to down-

Figure 7.6 Design and mold fabrication in the future

The introduction of a Process Management System streamlines processes, monitors their progress, and effectively manages workload For this purpose, the organization selected the “Dr Koutei Pro” system, which is developed by CIM Technology, Co., Ltd.

"Koutei," referring to a step in manufacturing, has been enhanced by integrating XVL technology, allowing for mold fabrication without traditional drawings This advanced system outlines processing procedures and the necessary man-hours for each component By aggregating the total man-hours for multiple mold fabrications, it identifies areas of concentrated workload Consequently, processes that demand excessive man-hours are restructured to balance the workload effectively.

The system inputs actual values based on the company's manufacturing progress, allowing for daily updates to the management plan By totaling and distributing these results each day, it facilitates the rescheduling of processes as necessary.

Operators utilize parts diagrams and Gantt charts to outline daily work procedures and details The integration of 3D part data with the process management system enhances efficiency, enabling real-time monitoring of manufacturing processes, progress, and product information This system promptly identifies issues, such as problems with specific mold parts, facilitating quick resolution and improved workflow.

Figure 7.7 Outline of process management system

Figure 7.8 Integration of process management system and XVL data

Changes in Information Transfer Media with Increased Use

Figure 7.9 shows the changes in the design tool at YAMAGATA CASIO, and how, as a result, their media for transferring information have changed In the

In the 1990s, the transition from traditional drafting to 2D CAD marked a significant shift in design practices Despite this advancement, many professionals continued to rely on parts drawings to convey essential product management details, including dimensions, tolerances, and materials By the latter half of the decade, further innovations began to emerge, enhancing the efficiency and accuracy of product design processes.

3D CAD and were finally able to replace shape and dimension data with 3D data

The method of conveying information shifted from drawings to technical meetings for design changes and finished states However, mold inspection specifications required written instructions in the form of 2D drawings, while assembly procedures were documented on paper to guide the assembly of parts Consequently, this information was communicated to downstream processes using traditional paper methods.

YAMAGATA CASIO is currently utilizing a 3D digitizer to assess 3D products, generating a point cloud that is compared to the original XVL model This comparison highlights differences through a color map, enabling the company to efficiently identify warps and deformations in the final product.

7.6 Changes in Information Transfer Media with Increased Use of 3D Design 77

Figure 7.9 Transition of design tool and information transfer media

The company successfully transitioned from 2D paper drawings to digital data through the introduction of XVL, a 3D data format that facilitates 3D representation and information integration Utilizing tools like XVL Web Master and XVL Notebook, they enabled the sharing of attribute information across different sections, fostering drawing-less communication However, 3D data alone cannot encompass all the technical information necessary for manufacturing Therefore, a system that automatically associates technical details with 3D models and distributes this information digitally is essential.

YAMAGATA CASIO has revolutionized its manufacturing process by transitioning from traditional 2D paper methods to a fully integrated 3D approach for both software and hardware This shift has fostered a 3D culture within the company, significantly reducing development time and enabling rapid, intensive production This transformation marks a groundbreaking advancement in the company's operational efficiency.

XVL-based Technical Information Distribution Key to Success

YAMAGATA CASIO achieved success in digitalizing information distribution through three key strategies The first strategy involved establishing clear guidelines for sharing technical information with external stakeholders and facilitating communication across various departments within the company.

The company emphasizes the importance of establishing rules for consistent communication of design intent, particularly regarding tolerance, finished state, and jointed state Additionally, automating the translation and flow of information is crucial, as busy designers often avoid tedious tasks that hinder their productivity.

Figure 7.11 Efforts for drastic reforms in manufacturing process

Effective distribution of technical information is crucial for downstream processes, necessitating automation to reduce unnecessary work A key component is the availability of a 3D viewer to facilitate the sharing of shape information, assembly details, layers, and attributes The ability to search for and extract relevant attribute information from large datasets is essential, along with accurately documenting changes and differences Currently, the company utilizes XVL Notebook to manage these tasks With a fully developed 3D infrastructure, enhancing the communication of design and technical information will be vital to support manufacturing operations.

Figure 7.12 Further progress of information distribution in future by 3D data

Report-less and Drawing-less in Mold Making

ALPINE PRECISION is essential to ALPINE's global operations, specializing in the production of on-vehicle information systems, including car audio and navigation systems The facility primarily focuses on manufacturing mechanical units and exterior components for vehicles Additionally, ALPINE PRECISION acts as the main hub for ALPINE’s international production facilities.

ALPINE PRECISION has been a leader in adopting 3D CAD technology to enhance their design processes In 2003, the company transitioned to a fully drawing-less and report-less information exchange system, utilizing XVL for effective communication across departments, including offshore teams This innovative approach has yielded significant benefits, integrating 3D data into various aspects of design and manufacturing, from mold design to production and maintenance This chapter presents a groundbreaking case study of ALPINE PRECISION, featuring insights from Mr Shigeki Yoshihara and Mr Nobuyoshi Mizuno of the Die and Mold Making Department.

Weapons for Global Expansion and Delivery Time Reduction

The globalization of the Japanese car industry and the demand for shorter market cycles have necessitated rapid communication between die and mold design and manufacturing departments To meet tighter deadlines, sharing 3D shape and attribute information is crucial, as it minimizes information transfer losses and boosts productivity Additionally, incorporating mold manufacturing data facilitates information sharing with overseas teams Utilizing 3D data is essential for the global expansion of the manufacturing sector and for reducing product delivery times.

Since the 1990s, ALPINE PRECISION has utilized 3D CAM systems in mold-making and began implementing 3D CAD for design in 2000 to enhance their digital manufacturing processes Despite these advancements, the company faced challenges in fully leveraging 3D CAD data due to difficulties in sharing 3D information and related attributes internally.

To maximize sharing of digital data – and ultimately eliminate all use of draw- ings and reports – the company launched a campaign to use lightweight 3D data in 2003.

Limitations of Business Activities Based on Drawings

ALPINE PRECISION encountered significant challenges with traditional mold-making methods that relied on 2D drawings despite their use of 3D design The need for 2D drawings introduces variability based on individual skills, affecting the preparation of cross-sections and size specifications This skill disparity can lead to misunderstandings, particularly among teams from diverse educational backgrounds and countries Additionally, the reliance on 2D drawings hampers the ability of different departments to work concurrently, delaying the manufacturing process To improve delivery times, it is essential for tasks such as acquiring parts information and initiating manufacturing preparations to occur simultaneously, which is difficult when using conventional drawings.

The challenge of generating extensive reports for mold making requires significant time investment, as these reports must clearly present all essential information for the manufacturing process.

Figure 8.1 Problems in mold design and manufacturing process

Use of 3D Data for Mold Design Review

When handling large-scale tasks, data input errors are likely to happen, leading to significant losses in subsequent processes The reliance on paper-based documentation, such as reports, hinders the improvement of work efficiency and the swift transfer of information between departments.

The transfer of information poses a significant challenge in manufacturing, as traditional methods rely on physical distribution of paper-based drawings and reports across departments This approach complicates the sharing of essential data for mold making and hinders the focus on critical manufacturing conditions Additionally, it limits the ability to relay manufacturing feedback and requirements back to the design teams With mold-making operations increasingly expanding internationally, efficient information transfer from headquarters to diverse manufacturing bases worldwide has become crucial.

ALPINE PRECISION recognized a stagnation in work efficiency related to drawings and reports, prompting the need to integrate essential attribute information for mold making into lightweight 3D data accessible across the company They determined that for effective utilization, 3D mold data must be lightweight, highly accurate, and responsive, ensuring compatibility with even budget-friendly PCs in the manufacturing department Additionally, the 3D viewer needed to be user-friendly for staff unfamiliar with complex software while also accommodating attribute information To meet these criteria, ALPINE PRECISION opted to implement XVL in their operations, successfully transforming their mold-making processes through the use of advanced 3D data.

8.3 Use of 3D Data for Mold Design Review

In the mold design process at ALPINE PRECISION, the design department collaborates with related departments to review molds from both procedural and manufacturing perspectives Initially, these reviews utilized 2D drawings derived from 3D CAD models However, this approach presented challenges, as individuals lacking drawing interpretation skills struggled to understand the mold's proper shape, limiting participation from staff outside the design team.

To enhance the review process, ALPINE PRECISION initiated the conversion of mold shapes to XVL once the drawings were finalized, addressing potential delays caused by late drawings This automated generation of XVL upon design completion allowed both technical and manufacturing departments to conduct timely and precise reviews, significantly improving their understanding of the design intent.

Before implementing XVL, the design department communicated feedback on CAD models through comments and screenshots, which were then sent to manufacturing for review With the introduction of XVL, design review results are now directly annotated on CAD models and converted to XVL format This streamlined process enhances communication between the design and manufacturing departments, ensuring clarity and simplicity.

ALPINE PRECISION has streamlined its mold-making process by having its design, technical, and manufacturing departments preview 3D models from their unique perspectives This collaborative approach allows team members to discuss feedback and conduct design reviews (DR) using XVL technology, significantly enhancing DR efficiency XVL serves as a clear visual record, as comments are directly annotated on the 3D models, fostering paperless communication and efficient information sharing across the company This process ensures that manufacturing requirements are communicated back to the design department, ultimately improving design quality.

Company-wide Sharing of Design Information

To effectively utilize 3D XVL mold data across the organization, it is essential that the XVL data encompasses not only shape information but also crucial production specifications and parts details that support downstream processes Designers can enhance the 3D CAD model by incorporating this vital data, which is then seamlessly converted to XVL format The lightweight nature of XVL allows it to efficiently manage shape information.

Figure 8.2 Use of 3D data in product review by design/technology/manufacturing departments

8.4 Company-wide Sharing of Design Information 85 and attribute information on the web at the same time The tool to support this is

The XVL Web Master facilitates the automatic creation of mold assembly drawings and parts lists, which can be easily shared across the network Utilizing XVL Studio, users can browse parts and mold attributes, measure shapes accurately, and view cross-sections This seamless integration allows the design department to share 3D and attribute information with the manufacturing department in real-time At ALPINE PRECISION, the manufacturing process is now entirely drawing-less, with all necessary data available for download in XVL format, leading to the elimination of traditional manufacturing reports By incorporating manufacturing sizes and conditions into XVL files, the overall mold quality has improved The manufacturing team also contributes additional data during the mold assembly stage, ensuring that the final XVL data, which encompasses all manufacturing information, is accessible company-wide.

3D communication offers significant advantages over traditional drawing-based methods by providing an intuitive understanding of the relationships between parts This enhances precision and efficiency in the manufacturing process, enabling workers unfamiliar with drawings to visualize the designed shapes in three dimensions, thus clarifying information that might otherwise be ambiguous.

Figure 8.3 Development of mold information at mold design department

The clarity of 3D ALPINE PRECISION drawings enhances data visualization, allowing for precise measurements and visual checks of cross-sections This improved understanding minimizes inquiries directed at designers and boosts overall work efficiency within the organization.

In this way, ALPINE PRECISION succeeded in switching from a drawing- based and report-based communication system between design and manufacturing

Figure 8.4 Acquisition of mold information and addition of information in manufacturing process

Figure 8.5 After XVL introduction, succeeded in realizing zero drawings and zero reports

Review by Mold Manufacturing Department

The transition to an XVL-based communication system has enhanced design efficiency by 40% Previously, the reliance on manual drawings required time-consuming decisions about cross-section representation and tolerance settings However, the new method eliminates the need for drawing skills, leading to a significant reduction in human errors related to drawings and reports.

XVL technology replaces traditional drawing and reporting methods, significantly increasing the volume of information compared to 2D drawings This efficiency allows for more design reviews (DRs), further improving design quality The accurate and timely information exchange between the mold design and manufacturing departments strengthens their collaboration, leading to enhanced productivity in both measurable and unmeasurable ways.

8.5 Review by Mold Manufacturing Department

The manufacturing department at ALPINE PRECISION utilizes XVL for operational simulations to identify and resolve issues prior to trial production, determining essential factors like actual mold size The outcomes of these reviews are documented as mold history information in XVL Studio Furthermore, by publishing XVL data through XVL Web Master, the information is easily shared with downstream departments, enhancing collaboration and efficiency.

Figure 8.6 Review of manufacturing in prototype stage of mold manufacturing

ALPINE PRECISION integrates maintenance and manufacturing data by providing feedback to the design department, utilizing XVL for pre-production previews Defect information from mass production is documented as maintenance data and transformed into a web-accessible format This valuable information aids in the development of new molds and enhances maintenance procedures.

Drawing-less and report-less mold making facilitates immediate communication of manufacturing issues to relevant departments, such as design and maintenance, ultimately improving mold finish quality and manufacturing speed The integration of XVL in mold design and manufacturing processes offers three key advantages.

Immediate access to parts information enables earlier manufacturing preparations, a significant improvement over traditional 2D drawing methods that made obtaining such data challenging.

2 All related departments can share the manufacturing information, enhancing mold quality By incorporating actual size information and mold-making condi- tions in XVL, the mold finish quality is improved

Incorporating manufacturing requirements into the XVL during the mold-making review facilitates the accumulation of manufacturing knowledge, enabling effective feedback from the manufacturing department to the design department.

Figure 8.7 Review of manufacturing in mass production stage of mold manufacturing

Application of 3D Data to Manuals

Information sharing can be effectively implemented internationally, enhancing problem resolution for offshore operations Previously, issues abroad were addressed through photographs and extensive discussions, which proved to be slow and cumbersome, hindering prompt troubleshooting Utilizing 3D data communication, particularly with lightweight XVL, facilitates a clear and immediate understanding of problems By sharing mold history and parts information with overseas production bases, companies can now respond to and manage issues more efficiently XVL serves as a vital communication tool, delivering accurate and timely information to the relevant departments.

8.6 Application of 3D Data to Manuals

ALPINE PRECISION is set to enhance its operations by centralizing XVL data within a robust database system, which will facilitate secure information sharing with international divisions and partner companies Additionally, the company aims to leverage XVL animation and illustration capabilities for creating comprehensive manuals With this strategic focus on information management, ALPINE PRECISION is poised to strengthen its mold design and manufacturing processes, establishing a formidable foundation for its production activities.

Figure 8.8 Development to overseas bases

Visualization of Manufacturing Information Mold Making Using 3D Work Specifications

TOKAI RIKA, a leading manufacturer of car parts, has transformed its operations by integrating 3D data into its mold-making processes This strategic shift from traditional paper methods to digital 3D data has significantly enhanced their in-house capabilities By implementing a unique coloring system for work specifications, the company has improved engineering communication and efficiency in mold design, leading to greater success in their production operations.

Tasks and Solutions in Mold-making Departments

To meet the demands of shorter car product lifecycles, parts manufacturers are under pressure to reduce delivery timelines, prompting a need for improved design and manufacturing processes TOKAI RIKA recognized this challenge and began using 3D CAD for mold design, while their manufacturing department still relied on 2D drawings This approach led to inefficiencies, as engineers often struggled to interpret the designs accurately, necessitating additional consultations with designers To streamline the mold-manufacturing process, TOKAI RIKA adopted XVL in 2003, transitioning to 3D data for mold-making operations They sought an intuitive 3D viewer that allowed for easy surface color changes to enhance clarity and efficiency in their operations.

(2) it is easy to measure, and (3) they are able to convert from various kinds of

3D CAD data to viewer data There were several viewers available meeting these requirements, so they further added three more requirements: (4) lightweight data,

(5) able to run on existing low-end PCs, and (6) could be supported by TOKAI RIKA’s information system department Based on all these requirements, the company chose Lattice XVL.

Using XVL and Advantages

Traditionally, after the mold shape was designed using a 3D CAD system, design staff would create drawings for manufacturing engineers, resulting in a sequential workflow However, in the XVL-based process, once 3D design is finalized, the CAD data is converted to XVL format and promptly sent to the mold-making department This allows manufacturing engineers to incorporate machining accuracy and work processes directly into the XVL data, streamlining the overall production process.

The design department specifies machining accuracy and methods using distinct colors on the CAD model, which are preserved in the XVL model The manufacturing department utilizes this color-coded information, considering the operational status of machining facilities, to determine the appropriate machine for each surface—whether it be die-sinking electric discharge machining (EDM), wire EDM, or general machining Subsequently, they update the surface colors to reflect the selected machining methods.

Figure 9.1 Conventional mold drawing (drawings were colored)

TOKAI distinguishes itself by utilizing XVL Notebook for creating NC programming specifications This innovative tool enables the preparation of dynamic 3D documents that seamlessly integrate 3D shapes and images, providing comprehensive views of molds along with detailed drawings Its functionality is akin to the detailed and overview maps found in car navigation systems, enhancing the clarity and precision of NC programming.

Figure 9.3 Example of expression by coloring in manufacturing process

Figure 9.2 Mold design and flow of XVL data in the manufacturing department

RIKA, known as "mold meisters," utilize the XVL Notebook to provide detailed program instructions and share their expertise with staff For instance, they can specify machining requirements, such as leaving a 1-mm machining allowance for future processes, while visually illustrating the relevant parts.

The NC program specifications are stored on a centralized server for easy access by staff members responsible for programming CAM systems These staff follow the provided guidelines to ensure accurate machine operation Mold specification documents created with XVL Notebook allow for magnified views of machined parts, linking these detailed displays with the overall 3D model for quick reference This clarity contrasts with traditional drawings, which often lacked precision in identifying specific parts XVL Notebook has significantly improved the ability of mold meisters to communicate their expertise and knowledge effectively.

The mold-making department has effectively implemented XVL Notebook documents for various applications, including measurement instructions for parts, as illustrated in Figure 9.5 Traditional measurement specifications derived from overview drawings are often time-consuming to prepare and challenging to interpret In contrast, XVL Notebook documents allow users to verify measurement locations by integrating images with 3D data, significantly improving comprehension Additionally, the use of 3D data streamlines the preparation of specifications, thereby enhancing manufacturing efficiency through collaboration with the design department.

Figure 9.4 NC programming specifications from XVL Notebook

Using XVL in the Manufacturing Department

Figure 9.5 Mold measure- ment specifications from XVL

9.3 Using XVL in the Manufacturing Department

Some employees in the design department initially resisted the company's adoption of XVL for design and manufacturing, as transitioning from familiar methods can be challenging The implementation of XVL increased the mold design workload, requiring additional tasks such as adding colors to models However, the company successfully encouraged cooperation by highlighting the significant improvements in downstream processes Meanwhile, the mold-manufacturing department embraced XVL, actively integrating it into their operations and creating operational manuals With a commitment to reducing mold design and manufacturing lead times, the mold-manufacturing department aggressively adopted XVL, recognizing that traditional drawing-based processes were insufficient for achieving these goals Figure 9.6 illustrates the manufacturing department's use of XVL for shape verification.

In 2002, the information systems department initiated educational presentations to promote the use of XVL across the company, tailoring materials such as technical introductions and case studies for different departments Key manufacturing personnel were consulted to enhance these case studies, and management actively supported these initiatives to reduce lead times Occasionally, management collaborated with the information systems department to further advocate for XVL, resulting in its gradual adoption throughout the organization.

How 3D Has Improved Operations at TOKAI RIKA

By implementing XVL technology, TOKAI RIKA's mold design department has significantly reduced the need for detailed dimensions in their designs Although some partner companies still rely on traditional drawings, the overall process has been simplified, allowing machinists to directly measure mold sizes using XVL data Previously, any missing size information on drawings led to blame directed at the design department from manufacturing.

XVL enhances manufacturing time estimation by utilizing 3D data for precise measurements of machining scope, area, and perimeter, leading to accurate time predictions This ensures that machining concludes as scheduled, facilitating timely mold making Additionally, XVL is cost-effective to implement, as it only requires an affordable PC for viewing, while editing and measuring XVL models can be done with low-cost tools.

TOKAI RIKA's implementation of XVL stands out due to its innovative approach to expressing machining accuracy through color-coded model surfaces Previously, the manufacturing department manually added colors to drawings, a task rendered obsolete by XVL, leading to a significant reduction in man-hours Additionally, traditional drawings faced challenges with complex shapes, as it was difficult to color hidden parts effectively.

Figure 9.6 Checking XVL at worksite

From 2D Drawings to 3D Drawings

3D shapes can have color added to any surface, and the manufacturing department follows standardized coloring rules that help convey machining details through colored models Previously using various CAD systems, the mold design department has now adopted XVL as a common format, allowing them to realize the benefits of 3D modeling As a result, staff in the manufacturing plants are beginning to experience the same advantages that designers enjoyed when transitioning from 2D CAD to 3D CAD.

TOKAI RIKA is expanding the use of XVL, a 3D format, from molds to product design, and is developing a system to generate XVL for every 3D CAD model Once the initial design is complete, related staff are notified via email to review the design, utilizing XVL for those without CAD access This shift is positioning XVL as the standard 3D format within the company, as it can be integrated into documents and is being adopted by downstream departments like production, inspection, and manufacturing Although these departments initially preferred traditional drawings, the growing diffusion of 3D design has sparked interest, leading to a company-wide mandate for all drawings to be in 3D, further promoting the use of XVL.

XVL has gained popularity as an effective tool for assembly process design reviews, prompting TOKAI RIKA to implement a system utilizing XVL Web Master for delivering 3D product assembly instructions to their manufacturing plants and international facilities This 3D approach has proven particularly beneficial for communication with overseas partners where language differences exist Additionally, TOKAI RIKA is encouraging its partners to adopt XVL, as many lack 3D CAD capabilities For those subcontractors without CAD, XVL data has proven to be more than adequate, while 3D CAD data is provided to those who do utilize it.

When releasing 3D data to external parties, companies face significant security challenges, making integrated security measures essential Currently, TOKAI RIKA adheres to security protocols for exchanging XVL data related to 3D CAD The company aims to distribute 3D shape information and product assembly animations to its mold-maintenance bases both in Japan and internationally To broaden the application of 3D data, TOKAI RIKA plans to implement practical security rules As a leading manufacturer, TOKAI RIKA exemplifies the shift from traditional color drawings to the use of XVL for enhanced 3D data utilization.

TOKAI RIKA has significantly enhanced their business efficiency by integrating 3D data into their processes This case study highlights how the manufacturing department's adoption of 3D data has inspired its use in the design department as well The findings demonstrate that lightweight 3D technology is increasingly preferred over traditional 3D CAD/CAM/CAE systems.

Figure 9.7 Assembly process distribution from XVL Web Master

CASIO: Creating Customer Manuals Using

CASIO, a prominent manufacturer of digital cameras and electronic dictionaries, exemplifies innovative 3D documentation practices While generating illustrations from 3D data is technically straightforward, the challenge lies in determining the responsible parties for preparing this data and promoting its usage This chapter highlights the initiatives of Mr Mitsuhiko Iwata, Manager of the Development Department within the Technical Division's Design System Development Group.

Mr Hideo Kashiwaguma, Manager of R&D, CASIO XVL was first applied to user documentation and then it spread throughout the company as a communication tool.

After 3D Design Practice Started Kicking In

CASIO is a leading manufacturer of a wide variety of electronic equipment, including consumer products like calculators, digital cameras, and watches, as well as information technology devices As the lifespan of electronic products decreases, the company faces the challenge of accelerating product development cycles To address this, CASIO's Development Department focuses on creating and enhancing design IT tools for all its products, playing a crucial role in reducing development time The implementation of CAD technology, which began with 3D CAD in the early 1990s and included the adoption of PTC in 1998, marks a significant milestone in streamlining their business processes.

CASIO adopted "Pro/ENGINEER" as its standard 3D design tool for PCs, beginning to utilize 3D data in 2002 after building a substantial data pool This integration of 3D data significantly enhanced their manufacturing processes across various business activities The company's objective was to implement 3D data in their design, quality, mold, and materials departments, aiming to restructure their operations under the concept of "Single Source Multi Use." CASIO selected XVL for its lightweight and user-friendly 3D format.

100 10 CASIO: Creating Customer Manuals Using 3D Data

Figure 10.3 illustrates the significant advantages of using XVL over traditional CAD data, highlighting how the CASIO EXILIM digital camera compresses 20 MB of data to just 0.4 MB This compression not only minimizes data volume but also dramatically reduces the data transfer time to subcontractors to one-ninetieth of the original duration As CASIO shifts from manual creation to outsourcing, these efficiencies are crucial for streamlining operations.

Figure 10.1 Adoption of CAD at CASIO

Figure 10.2 Reason for using XVL

e-Manual Project

Sending 3D data to subcontractors for illustration preparation has generated excitement due to the significant reduction in data transfer time.

CASIO pioneered the use of XVL technology to develop e-manuals for their products, aiming to streamline the manual creation process by leveraging CAD models during the design phase This innovative approach allowed CASIO to expedite manual production and accurately estimate completion timelines, while still accommodating design changes through effective communication with subcontractors For user manuals, CASIO assigned tasks to subcontractors, providing them with detailed instructions, whereas service manuals, primarily internal documents, were also prepared by subcontractors using XVL Studio to create exploded views Initially, CASIO supplied large CAD data files, which proved cumbersome for subcontractors; however, the transition to XVL significantly improved data transfer efficiency and reduced workload, enhancing the overall manual preparation process.

Figure 10.3 Data compression and transfer evaluation using actual data

102 10 CASIO: Creating Customer Manuals Using 3D Data

Adopting e-manuals offers significant advantages, including substantial annual savings of tens of thousands of dollars by minimizing the time needed for illustration creation Additionally, the manufacturing benefits that accompany this transition further enhance efficiency and productivity.

1 Achieved faster delivery time by starting manual preparation early using the design data

2 Eliminated errors by giving the manual creators product shape and structural information

3 Reduced enquiries to the design department during the manual creation process

4 Eliminated the need for the sample products that were necessary for manual creation in the past

5 Completely eliminated inefficient large data transfers for musical instruments and printers

CASIO designers have noted a significant reduction in inquiries about sample assembly and manual creation during peak development times Launched in 2002, the e-Manual Project initially covered 12 models, including digital cameras and musical instruments, and has since expanded to include numerous products due to its proven benefits Users have appreciated the improved consistency in illustration quality and a decrease in errors Digital manuals are provided with products and available on websites, while service manuals are distributed to thousands of recipients via CDs or the Intranet, utilizing vector data generated from XVL.

The use of XVL technology has enabled the creation of detailed manuals for the CASIO EXILIM digital camera and XJ Projector, as illustrated in Figure 10.4 Additionally, CASIO is now leveraging XVL for internal technical documentation, utilizing the 3D image data generated for producing assembly drawings and quality assurance reports.

Figure 10.4 Example of use (instruction manuals)

CASIO is transitioning from traditional 2D images to 3D data for internal documents and e-manuals, recognizing the effectiveness of 3D animations in enhancing communication The company has developed 3D service manuals for overseas dealers, which are created by the service department and distributed online These animated manuals provide clearer understanding compared to text descriptions Additionally, CASIO is utilizing viewer products to integrate XVL as a versatile communication tool, marking its evolution from user documentation to animated service manuals and broader 3D communication applications.

Figure 10.5 Example of use (service manual)

Figure 10.6 Developments of 3D data uses in the future

104 10 CASIO: Creating Customer Manuals Using 3D Data

Driving Force Behind Use of 3D Data

CASIO's seamless integration of 3D data is driven by three key factors: collective conversion to XVL, expansion support activities, and strong management backing Batch conversion to XVL allows users to easily access 3D data through a web-based system Utilizing Pro/INTRALINK, CASIO provides a user-friendly web interface where anyone can request a model, which is then automatically converted to XVL This system benefits designers by eliminating additional workload, as they only need to check CAD data into the management tool, while users can effortlessly obtain XVL data online CASIO has invested significant resources into developing this efficient batch conversion system, ensuring it meets the needs of both designers and downstream users, including subcontracted manual creators.

The second key factor driving the adoption of XVL was the promotional activities and materials developed by the head office, as illustrated in Figure 10.8.

2 Training sessions for XVL tools

3 In-house web portals containing XVL support materials

Figure 10.7 Construction of web-based XVL conversion mechanism

Online Data Reviews

This focused initiative effectively promoted XVL by demonstrating the benefits of 3D data As users from various departments recognized the advantages of 3D data, they began to incorporate it into their own workflows.

The successful adoption of XVL at CASIO was significantly driven by the strong support from company management Executives recognized its effectiveness in improving business processes and embraced best practice stories associated with XVL This enthusiastic backing positioned XVL as a valuable tool for enhancing business operations, leading to widespread utilization of 3D data across the organization.

2003, the group promoting the use of XVL was awarded the president’s prize Such high recognition motivated everyone throughout the company to start using 3D data

CASIO has significantly broadened the application of XVL, evolving it from a documentation tool to a comprehensive communication resource utilized across the organization The service department leverages animated 3D service manuals, while the manual department employs XVL for crafting user manuals Additionally, the design department utilizes XVL for collaborative meetings with manufacturers, and the engineering department incorporates it for drawing inspections.

Figure 10.8 XVL development support activities

106 10 CASIO: Creating Customer Manuals Using 3D Data

Figure 10.9 Development state by department

Figure 10.10 Use in online design review

CASIO has integrated XVL technology for shape verifications during meetings with mold manufacturers and is expanding its use across various departments, including materials and production Currently, XVL facilitates online design reviews (ODR) company-wide, eliminating the need for in-person meetings that were costly and often hindered by scheduling conflicts or difficulties in interpreting engineering drawings This innovative approach streamlines the review process, making it more efficient and accessible for all parties involved.

The Online Dispute Resolution (ODR) system enables global participation through phone and online bulletin boards, as illustrated in Figure 10.10 Utilizing XVL models simplifies understanding compared to traditional engineering drawings, allowing for unrestricted participation in design reviews CASIO plans to integrate XVL technology into more business activities, responding to the growing competition in product development amid shorter digital equipment lifespans With its innovative use of 3D data, CASIO is poised for future advancements, staying ahead in the industry.

KVAL: 3D Information Sharing and Its Effects at a Middle-scale Firm

The use of 3D data is not limited to large corporations; small and medium-sized enterprises can also leverage its benefits KVAL Inc., a woodworking machinery manufacturer in the USA with around 100 employees, exemplifies this potential According to Sebastien Jame, Engineering Services Director at KVAL, the adoption of XVL compression technology has led to significant improvements in their operations They have experienced productivity gains of 20–25% in manufacturing, reduced technician learning curves from days to mere minutes, and a decrease in spare part service calls.

15 to 20 minutes to just seconds.” This chapter introduces the use of 3D data at a middle-scale firm as seen from the case study of KVAL.

Use of 3D Data for Maintenance of Complicated Machines

KVAL, a family-owned company established in 1947, specializes in designing and manufacturing heavy industrial woodworking machinery, particularly renowned for its precision-engineered door machining equipment With over 60 years of experience, KVAL has adapted to increased competitiveness in the millwork industry by customizing its machines to meet the specific needs of specialized customers The company produces and installs more than 300 unique machines annually, each often comprising up to 6,000 individual parts KVAL also maintains a robust presence in the field, with over 10,000 machines currently in operation.

A.A Kvalheim, the founder of the company, revolutionized the industry by designing a panel saw with an innovative traveling carriage, positioning the company as a leader in precision-engineered door machining design and manufacturing.

KVAL, a middle-scale firm specializing in millwork equipment, has recently implemented SolidWorks, a robust 3D modeling solution, to enhance their custom design services While they successfully utilized SolidWorks’ eDrawings feature for sharing 2D designs, challenges arose with 3D data due to the large file sizes associated with KVAL's machines This resulted in slow loading, viewing, and manipulation of 3D models, highlighting the need for more efficient tools to improve their business processes.

XVL effectively addressed the issue by evaluating and discovering the capability to generate 3D files that are significantly smaller than eDrawings files, while maintaining high performance even on budget-friendly PCs By integrating SolidWorks for 3D model creation and XVL for sharing, assembly and reworking times were reduced by up to 20%, allowing KVAL to reap the initial benefits outlined in the chapter Additionally, KVAL overcame internal communication barriers, often referred to as "heavy doors," by implementing a new communication strategy centered around 3D data.

Opening the Door Between Design and Manufacturing

Engineering designed a customized automatic door milling machine based on specific customer requirements and sent it to the production floor, assuming everything was fine However, issues often arose regarding the manufacturability of the design, leading personnel to return marked-up drawings to Engineering This communication gap stemmed not only from their physical separation but also from a technological barrier, as Engineering used CAD software while Manufacturing relied on traditional paper methods.

Figure 12.1 Comprised of KVAL computer-controlled manufacturing machines and many parts

Use of 3D Data Between Manufacturing and Technical Support

After implementing Lattice 3D technology in the Design department, KVAL experienced significant benefits, including reduced CAD model changes and enhanced collaboration between Design and Manufacturing The use of 3D data is essential for accurately communicating complex machinery, allowing welders to efficiently plan assembly sequences This innovative approach transformed the design and manufacturing process into a cooperative effort, enabling designers to access valuable insights from the production floor Despite Manufacturing's initial lack of CAD knowledge, the adoption of XVL format and user-friendly animation tools led to increased productivity and minimized rework.

11.3 Use of 3D Data Between Manufacturing and Technical Support

In just a few months, the compression innovation has had a similar effect on KVAL Technical Support and Service Often the customer, while looking at their

Figure 12.2 KVAL machine XVL model in manufacturing

KVAL, a middle-scale firm, faced challenges in providing timely technical support due to the reliance on paper drawings for customized machines To enhance service quality, they implemented the XVL Web Master tool, allowing technical staff to manage parts lists and view 3D models directly on their desktop PCs This innovation enables technicians to virtually see and understand customer issues in real-time, significantly reducing delays and conversation lengths while accurately identifying parts by number What previously took 15-20 minutes is now accomplished in seconds, resulting in a 10% increase in productivity, reduced shipping errors, and improved customer satisfaction The 3D models created by the Design department are now effectively utilized by the Technical Service department, streamlining operations and enhancing service delivery.

Figure 12.3 KVAL Technical Service department using Lattice 3D models to handle customer queries

Future Plans: Aiming at 100% 3D

KVAL is set to enhance customer communication by utilizing 3D models, allowing clients to view their unique machines directly through the KVAL website or WebEx sessions The initiative aims for a complete transition to 3D, enabling customers to identify issues and order spare parts efficiently Instead of traditional paper manuals, KVAL will provide a portable computer equipped with Lattice 3D viewer and XVL files, including detailed assembly and disassembly animations This innovative approach facilitates collaborative problem-solving between customers and KVAL Field Service staff The XVL Web Master feature allows users to visualize the assembly process from any angle, significantly improving technical and maintenance training This interactive experience not only enhances understanding but is expected to drastically reduce maintenance time.

Figure 12.4 KVAL machine XVL model in Technical Service department

114 11 KVAL: 3D Information Sharing and Its Effects at a Middle-scale Firm

Figure 12.5 Sebastien Jame, Engineering Services Director at KVAL

KVAL is enhancing its operations by integrating lightweight XVL models with its ERP system, linking them to vital information like pricing and animated assembly models that leverage the expertise of assembly specialists for effective field repairs Jame expressed that the benefits realized in just five months with Lattice 3D’s applications and the XVL format have surpassed expectations, highlighting its significant impact on their entire operation For companies like KVAL, which specialize in customized systems, utilizing XVL for interdepartmental and customer communication is poised to bolster their competitive edge KVAL exemplifies how 3D data can serve as a robust source of competitive strength.

Promoting Company-wide Process Chain

MAN Nutzfahrzeuge AG, a prominent European manufacturer of trucks and buses, has adopted XVL as its primary format, particularly for 3D drawings Since January 2006, the MAN Commercial Vehicles Group has been automatically converting selected 3D design data into XVL, facilitating its distribution throughout the process chain Currently, the 3D XVL Player is installed on nearly every PC within the company This article explores the utilization of 3D data across MAN, drawing insights from an interview with Dieter Ziethen, Project Leader in the Information Technology CAE Group at MAN Nutzfahrzeuge AG.

Using 3D Data for Design, but 2D Drawings

The MAN Group, a prominent manufacturer based in Munich, specializes in a diverse range of vehicles, including trucks, buses, diesel engines, and turbomachines With annual sales reaching 13 billion Euros and a global workforce of 50,000 employees, MAN maintains a strong market presence in its core areas As one of Germany's top 30 companies, MAN AG is also a member of the DAX stock index, highlighting its significant role in the German economy.

MAN Nutzfahrzeuge AG, the largest entity within the MAN Group, manufactures 68,200 trucks and 6,000 coaches annually, generating revenues of 7.4 billion Euros and employing 33,000 individuals The company is actively promoting the use of 3D data and has recently integrated XVL technology into its operations.

The MAN Group is well-regarded in Europe for its commitment to integrating solutions that enhance business objectives and return on investment (ROI) To support this goal, the company has actively adopted 3D CAD systems; however, information exchange with downstream processes, both internally and with suppliers, has primarily relied on 2D drawings According to Dieter Ziethen, this approach presents challenges that need to be addressed.

MAN Nutzfahrzeuge AG aimed to transition from 2D to 3D design data across the company Despite the implementation of 3D CAD systems in design departments, most information remained in 2D The introduction of XVL technology has successfully facilitated the sharing of 3D design data, including essential design information and markups, throughout the entire organization.

Aiming at 3D Communication Throughout the Whole Process

As shown in Figure 13.1, MAN Nutzfahrzeuge’s motivation was to improve data quality and enable 3D data for the whole process chain, specifically for the follow- ing three reasons:

1 3D data can be visualized in the whole process chain because it is less abstract than a 2D conventional drawing

2 Because design is already done in 3D, the design departments will see a reduc- tion in time by avoiding the 2D drawing production step

Non-CAD-trained staff can effectively visualize and analyze design models, facilitating collaboration on a shared data foundation This includes enhancements like 3D animations for assembly and disassembly processes, as well as "exploded" views of individual parts.

To meet its objectives, the company required a unified communication framework that encompassed the entire process across all departments, regardless of the various CAD systems in use As a solution, they implemented XVL for its lightweight 3D data capabilities.

Figure 13.1 MAN process chain: XVL increases opportunities to use CAD data

Selecting XVL for its Lightweight and Interactive Features

12.3 Selecting XVL for its Lightweight and Interactive Features

The following are 11 reasons why MAN Nutzfahrzeuge decided to adopt XVL:

01 XVL is CAD-system independent and has converters for all significant CAD systems

02 XVL is a lightweight format with extremely high compression typically be- tween 1/50 and 1/250

03 With a single XVL file, measurements are also possible

04 XVL has a good integration capability with MS Office documents, and inte- gration with other systems is readily possible

05 XVL has a small memory consumption

06 XVL can be viewed on very inexpensive computers

07 XVL has the capability of generating 2D illustrations

08 XVL is accurate enough so that XVL data can be imported back to CAD sys- tems

09 XVL Player has good mouse operation integration on the freeware viewer

10 XVL has optional encryption security

11 XVL has constant 3D visualization quality in both zooming in or out

MAN Nutzfahrzeuge conducted extensive testing of XVL, validating its reliability, accuracy, scalability, and security Notably, a bus frame's data, originally 45 MB in CATIA, can be compressed to 630 KB or less without sacrificing precision This allows for accurate measurements of even the smallest details Dieter Ziethen expressed admiration for the high precision that XVL offers.

In a data conversion test flow involving formats such as CATIA V5, XV3, IGES, and STEP203, it was found that XVL is significantly smaller in size compared to IGES and STEP, while still maintaining high accuracy and retaining structural information Although some issues arose when data was returned to CATIA due to problems with XVL-generated files, dimensions remained accurate and posed no practical issues The company recognized that adopting XVL applications would enhance the use of 3D data, facilitating communication, visualization, measurement, and publication in various formats.

Multi-use of XVL Centering Around Data Management Tools

Internal Communication

The coach department has recently launched XVL and is in the process of integrating coach data into EZIS Within EZIS, users can click on a specific part from a parts list to access various functionalities, such as displaying a selected part view, deleting part views, and automatically generating exploded part views.

Communications with Suppliers

MAN will provide suppliers with XVL files or IGES files converted using XVL Studio, instead of sending CATIA files that contain critical design information This approach allows suppliers to reference the geometry and design data defined by MAN while ensuring security by using XVL files that have high but intentionally reduced accuracy.

Technical Illustrations

XVL significantly enhances the efficiency of technical documentation by allowing the use of 3D data to commence documentation development earlier in the process Its models support animation while maintaining exceptional compression, with outputs available in formats such as SVG illustrations, HTML pages, or 3D PDFs Looking ahead, the company intends to introduce 3D PDFs in Adobe format, leveraging XVL's versatility for a wide array of technical illustrations across various applications.

Assembly Instructions

MAN is transitioning from static images to animated instructions on 32-inch screens at assembly lines to enhance on-the-job guidance and training This shift aims to reduce the time and labor involved in preparing static visuals, providing clearer and faster operational instructions for workers.

Quality Assurance

To enhance quality assurance, MAN is transitioning from traditional 2D paper-based views to advanced 3D data for more accurate measurement point verification and geometry assessment Currently, quality assurance requires the creation of specialized QA drawings from scratch for each project However, future plans involve utilizing existing 3D data and XVL technology to generate 3D drawings, significantly decreasing information exchange time This approach will also facilitate the sharing of valuable information across various departments and with customers, improving overall efficiency and collaboration.

Dieter Ziethen envisions a future where the labor-intensive 2D drawing stage is replaced by efficient 3D digital models, simplifying tasks and enhancing understanding through dynamic, animated information MAN's investment in lightweight XVL 3D data, accessible on over 10,000 company PCs, positions it as a formidable competitive advantage in the industry.

In the manufacturing industry, the integration of 3D design through 3D CAD, virtual simulation via CAE, and the conversion to real objects using CAM is now standard practice However, leading companies are expanding the use of 3D data beyond design, applying it throughout the entire manufacturing process and into downstream activities like service and marketing This chapter explores best practices from Japan, highlighting effective strategies for utilizing 3D data and essential considerations for developing a robust 3D data system.

Best Practices for Successful Use of 3D Data

Design Review (DR) with Lightweight 3D

Lightweight 3D data plays a crucial role in facilitating Design Reviews (DR) between upstream and downstream departments, significantly enhancing delivery times and product quality by proactively addressing potential downstream issues The specific checks during DR vary based on the design stage and business nature, but the use of lightweight 3D data yields both direct benefits, such as reduced review times, and indirect benefits, including the prevention of downstream problems that can lead to costly design changes In fast-paced design environments where product shapes frequently evolve, DR is essential for verifying comprehensive designs Additionally, lightweight 3D data fosters collaboration by allowing experienced designers to mentor newcomers, providing a holistic view of the model that surpasses the limitations of CAD systems, and enabling manufacturing staff, who may struggle with 2D drawings, to engage actively in the review process This elimination of the 2D drawing barrier enhances collaboration between design and manufacturing, driving innovation and potentially leading to groundbreaking products.

Eliminating 2D Drawings and Reports

The second pattern involves utilizing lightweight 3D models to streamline business processes by eliminating the need for traditional drawings and reports Even when design teams leverage 3D data, overall design efficiency remains hindered if manufacturing still relies on drawings After completing a 3D design, designers often spend considerable time preparing drawings and reports for manufacturing, which detracts from productivity To enhance both design and manufacturing efficiency, it is crucial to integrate essential information, such as surface finish and tolerance, directly into the 3D CAD model This information must then be converted into lightweight 3D data for effective downstream distribution As highlighted in previous discussions, several companies have successfully transitioned to a drawing-free process.

13.1 Best Practices for Successful Use of 3D Data 123 reports from their business processes In order to achieve this, these companies have set standards for what is to be expressed in 3D, made rules for conveying information, and then established a system for automatically creating this informa- tion The Japan Automobile Manufacturers’ Association (JAMA) is currently trying to standardize the use of only 3D data for design information in the auto- mobile industry The goal is to replace 2D drawings by setting standards for 3D models and the viewers that interact with them The elimination of 2D drawings from the process chain provides the following benefits: (1) it reduces the time and work for preparing drawings, (2) it makes it easier to understand 3D models, shapes, and product features, and (3) since no 2D drawings are prepared, there are no inconsistencies between drawings and 3D models These 3D drawings will be used in many areas including production, services, and distribution Therefore they must be expressed in lightweight 3D data format No doubt, the use of 3D drawings will spread rapidly in the next few years.

Communicating with Lightweight 3D

Lightweight 3D data is essential for enhancing communication within companies and with partners, as it simplifies information for staff in manufacturing, quality control, and service departments Viewing 3D data on devices like notebook PCs during discussions or while reviewing e-documents greatly improves comprehension For instance, 3D representations of parts lists significantly decrease procurement errors Additionally, 3D data fosters a shared understanding among individuals from diverse backgrounds, ensuring everyone has a common grasp of the model.

Sharing a common understanding within the company and with suppliers can help prevent order placement and delivery errors Free lightweight 3D viewers allow clients and partners to easily access and verify designs By providing lightweight 3D models that include dimensions and annotations, subcontractors can effectively manufacture parts Although it's challenging to quantify the cost savings from using 3D data for communication, lightweight 3D models are poised to become essential tools in downstream processes, much like the Internet and email have become vital in the workplace.

Utilizing 3D data for creating illustrations in technical documents offers numerous advantages, such as faster delivery times, enhanced consistency in illustration quality, and lower costs for producing visuals This approach not only streamlines the illustration process but also improves the overall effectiveness of technical communication.

3D technology enhances illustrations by allowing the integration of 3D data into documents, essential for parts catalogs that require both geometry and configuration information, which XVL provides Additionally, dynamic digital documents featuring 3D animations can be created, making them ideal for assembly instructions in both local and international cell production Interactive 3D manuals offer a more comprehensible alternative to traditional paper manuals, covering a wide range of topics from manufacturing specifications to service and maintenance guides Looking ahead, companies will have the capability to distribute 3D instruction manuals directly to consumers.

The key to achieving success in projects is the effective acquisition and distribution of 3D data Often, the departments or subcontractors responsible for creating manuals are distanced from the design team and begin their work later in the process To successfully implement 3D documentation, it is essential to establish a system that allows for the rapid sharing of 3D data with downstream departments, significantly improving their work efficiency However, data security can pose challenges, particularly when external companies are involved in manual creation To mitigate these risks, some manufacturers opt to establish non-disclosure agreements regarding specific 3D data with their partners.

Lightweight 3D illustration and animation tools are rapidly evolving, with significant improvements on the horizon Currently, there are tools available that can automatically update illustrations in response to design changes, offering substantial cost savings The distribution of 3D data doesn't have to be complicated; as long as the distribution rules are well-defined, 3D data can be created manually today Soon, the use of 3D data for illustrations will become a standard practice.

Sharing of 3D Data on CAE and CAT Systems

The fifth pattern of successful 3D data use lies the sharing of CAE and CAT data

CAE and CAT data, previously utilized by a limited number of specialists, can significantly improve product quality when shared with designers and manufacturers Additionally, sharing historical design failures can serve as a valuable educational resource for new engineers The advent of lightweight 3D technology now enables the reduction and dissemination of CAE data, facilitating better collaboration and learning opportunities within the industry.

Utilizing 3D data in inspection departments offers significant benefits, especially as these areas often lag in IT adoption The introduction of non-contact 3D measuring devices enables the identification of discrepancies between CAD models and final products Additionally, this difference data can be easily shared across various departments through lightweight 3D formats, enhancing collaboration and efficiency.

Manufacturing process improvements depend on the support of manufacturing engineers, who often prioritize their routine tasks These engineers may hesitate to modify existing business processes to leverage 3D data However, once they experience the benefits and convenience of utilizing 3D technology, their perspective may shift, leading to greater openness towards process enhancements.

Systems that Aid in Successful Use of 3D Data

System for Storing 3D Data

Design information includes data before design approval and data after approval

Effective management of 3D data is crucial for design reviews (DRs) and factory parts checks, with DRs typically conducted before design approval and factory checks afterward Success hinges on a system that ensures timely access to the correct 3D data, as inefficient data retrieval can hinder productivity To facilitate DRs, pre-approved lightweight 3D data must be readily available, which requires clearly defining the storage location of the approved CAD data and the conversion process Companies can streamline operations by distributing 3D parts lists with pre-approved data to their plants or sharing this information with partners for DR purposes A web-based automatic conversion system can efficiently provide pre-approved lightweight data to authorized users, enhancing collaboration and efficiency.

Lightweight 3D data derived from post-design approval CAD data should be accessible to a wide range of users within the company To facilitate this, it is essential to store the lightweight 3D data in a centralized database system This data plays a crucial role in manual production and quality assurance processes Additionally, it is important to manage CAD data and lightweight 3D data together as a cohesive pair There are two main approaches to implementing such database systems.

1 Expanding and using the file management system, or

2 Managing data in the PDM system

The initial system is cost-effective and easy to implement, making it ideal for small to medium-sized businesses; however, it lacks a true database function In contrast, the second system is designed for large manufacturers, providing more robust capabilities.

Most large manufacturers already have PDM, be it self-developed or a commer- cially available tool So all that is needed is to integrate lightweight 3D into the existing system

The assembly structure and parts position information can vary across different CAD systems, necessitating corrections for consistency before saving in a data management system When using lightweight 3D data in manuals, modifications are often required, as parts catalogs may use different names than those defined in the CAD system Consequently, adjusting part names and structures to align with company rules is essential Utilizing XVL data, software is available to resolve these discrepancies, allowing the original CAD-converted XVL data to be transformed according to company specifications This process enables the automatic generation of XVL data that adheres to company guidelines, resulting in significant cost savings.

System for Ensuring Security

Lightweight 3D data offers the advantage of easy display, but it poses risks of data leaks that could compromise confidential information Therefore, establishing a robust security system is essential, while also ensuring that excessive restrictions do not hinder downstream processes Striking a balance between security and usability is crucial when formulating operational rules XVL technology enhances data access control through password protection and integration with in-house security servers, allowing only authorized personnel to access sensitive information It is important to define internal access rules prior to implementation and consider the security of related documents, such as design files and function charts Thus, an integrated security system is necessary, which XVL technology facilitates effectively.

13.2 Systems that Aid in Successful Use of 3D Data 127

Recently, the Japanese manufacturing industry has shifted focus from relocating plants to China to enhancing local production facilities This strategic move aims to foster technological innovation by integrating development and production processes The utilization of 3D data has proven effective in streamlining these systems within Japan, as well as facilitating design and production overseas The benefits of 3D communication and the advantages of leveraging 3D data to optimize business processes are increasingly acknowledged in the industry.

The journey of enhancing manufacturing processes through 3D data is just beginning, with numerous opportunities for improvement Automobile manufacturers are now showcasing CAE analysis results to potential customers at dealerships, highlighting their vehicles' quality Additionally, companies are leveraging 3D data in various innovative applications, including digital packaging systems, sales and marketing strategies, and 3D instruction manuals for consumers By generating lightweight 3D data and establishing secure systems for its application, manufacturers can unlock a vast array of data uses This innovative approach to lightweight 3D data is poised to become a significant competitive advantage for leading manufacturers in the years ahead.

Figure 14.3 Security measures for using XVL

XVL (eXtensible Virtual World Description Language) was created to help companies effectively utilize their "idle" 3D data generated after design processes in various departments, including maintenance, marketing, and sales This lightweight 3D data significantly enhances overall corporate efficiency In globally specialized manufacturing environments, collaboration among employees with diverse skills and backgrounds is essential, making clear visual communication crucial This article explores the development concepts behind XVL as a streamlined 3D format.

The Starting Point of the XVL Development Concept

Since the 1980s, the concept of using lightweight 3D data for surface representation technology, foundational to XVL, has existed Initially, research in CAD/CAM prioritized accuracy over data size However, in the mid-1990s, as the Internet gained traction, researchers began to shift their focus towards lightweight representation methods utilizing surface technology.

In 1997, VRML97 (Virtual Reality Modeling Language) was established as the ISO-standard method for 3D representation on the Internet However, it faced limitations as it utilized traditional aggregate clusters of polygons, making it difficult to transmit complex shapes due to the reliance on telephone lines at the time While the idea of 3D representation in a network environment was groundbreaking, its practicality was hindered by these technological constraints.

Lightweight surface technology significantly compresses large CAD models, achieving reductions of over 100 times This substantial decrease in data transfer time paves the way for integrating 3D into design and manufacturing processes, offering immense advantages This concept laid the foundation for XVL research.

After three years of trial and error, lightweight XVL was born at Lattice Tech- nology at the beginning of 2000 At this time, the development goals were:

1 To express 3D shapes accurately with only 1% of CAD data size Ten times compression is not enough; at least 100 times compression is necessary for the data to be of use in business processes

2 To convert all types of 3D data easily to XVL Given that the costs to create 3D data are very high, it is not ideal to create XVL data from scratch Be it CAD data, CG data, or costly scanned 3D data, a mechanism to automatically con- vert all 3D data is a must

3 To allow the data to be web-enabled The web is ubiquitous, so the data must be displayable in network environments

3D XVL enhances communication by reducing CAD data and integrating it with production structural information, utilizing net-friendly XML (eXtensible Markup Language) Additionally, XVL's support for comments and hyperlinks transforms 3D shapes into effective search tools.

Lattice also developed a technique to automatically generate data from diverse 3D data such as CAD and CG, enabling XVL to be generated from most 3D CAD/CG systems

XVL is a cost-effective solution that integrates design and manufacturing information with 3D shapes, serving as a key reference for decision-making in these processes It facilitates the seamless use of 3D data throughout design and manufacturing, enabling applications such as 3D design reviews, parts lists, email collaborations, and work instructions This accessibility, termed “3D Everywhere” by Lattice, allows anyone to easily manage 3D data from any location Over the past seven years since XVL's inception, the manufacturing industry has embraced 3D CAD and the increasing accumulation of 3D design data, with the "3D Everywhere" concept being adopted by numerous companies to enhance the utilization of this data.

A.2 From Fast Display to Information Unification

Figure A.1 shows five technical features of the initial XVL Their details are dis- cussed below

A.2.1 Automatic Generation of Lightweight 3D Data

To facilitate the seamless use of 3D data, generating inexpensive and lightweight 3D data is essential The production of 3D data is often costly compared to image data, primarily due to the significant implementation, educational, and operational expenses associated with 3D CAD systems Therefore, the ability to efficiently convert existing 3D CAD data into XVL format is critical.

XVL significantly compresses all types of 3D data, such as 3D CAD, 3D CG, and 3D scan data, establishing a standardized format for 3D representation Notably, XVL files are approximately 100 times smaller than VRML, a polygon-based 3D format, as illustrated in Figure A.2.

Figure A.1 Five characteristics of XVL

Figure A.2 Comparison between VRML and XVL

Currently, there is commercially available software that can automatically convert various 3D CAD and CG data into XVL format Once the XVL files are created, they can be easily viewed by anyone using the free XVL Player.

A.2.2 High Data Accuracy and Small Data Size

Manufacturing departments use 3D data for cross-section display, measurement,

XVL technology excels in engineering applications such as NC tool path calculation and finite-element analysis by utilizing surfaces and boundary curves instead of traditional polygon data This innovative approach allows for the representation of CAD data with an impressive accuracy of 1/1,000 mm while maintaining minimal file sizes By transmitting only lightweight curves and surfaces over the network, XVL ensures efficient data transfer, enabling the receiving PC to generate high-quality images Additionally, XVL supports trimmed surface representations, which are essential for modeling complex shapes, resulting in P-XVL (Precise XVL) that combines both lightweight design and high precision.

Figure A.3 High-speed 3D data transfer by XVL