Improving Lean Manufacturing Through 3D Data
by Dr Hiroshi Toriya

Book Excerpt: An excerpt taken from the new book “Improving Lean Manufacturing Through 3D Data” by Dr. Hiroshi Toriya.

This new book is available free at www.lattice3d.com (registration required) in an e-book format from Lattice Technology.

In March 2008, Japan’s JAXA space agency launched the first part of its manned space experiment module to the International Space Station on the Space Shuttle Endeavour. The logistics module was installed first, and the onboard laboratory was installed on the Space Station later in 2008, and during 2009 the external experiment platform and pallet will also be installed. The module, codenamed Kibo, is a pressurized experiment platform that will be used across the next decade to conduct micro gravity experiments.

To develop this state-of-the-art equipment, 3D CAD was extensively used, and those 3D models are now expected to play increasingly important roles in the review of designs and operations as the module goes into operational mode. Yoshiki Hashiguchi of the Human Space Systems and Utilization Mission Directorate at JAXA, discusses the IT technologies supporting JAXA’s Kibo platform, as an example of how 3D data is being used not just for design and development, but also for full operations, maintenance and repair of orbiting space vehicles.

Using 3D data to Operate and Maintain Orbital Space Vehicles

Using 3D data to manage operations of orbiting space vehicles may seem a little counter intuitive at first glance, until you realize that just for the Kibo module there are 2 million parts involved, not including the rest of the space station. While the design teams were highly familiar with each of the parts, as operations teams were brought in so it was apparent that an intuitive database that contains not just list and operations data but also visual 3D data, was needed to allow operations teams to rapidly understand and manage the complex module while it operates for the next 10 years.

As the Kibo project started, so JAXA started to manage and collect the 3D data from the various teams. When the 3D CAD model of Kibo was ready, it was shared across the international teams and used to review various operations including construction simulation, onboard activities, and so on. From the start, 3D models have been used for the design and assembly of Kibo, providing the foundations for the use of 3D data. The 3D data was held in a standard database and used by the engineers as a tool for checking each design.

Because JAXA’s 3D database was so convenient, more and more operational information on Kibo was being uploaded onto the system simultaneously. But that growing usage also revealed various limitations in the basic system. The design teams were highly familiar with parts names and were easily able to find required parts information from the two million parts in the database. However, this proved extremely difficult for the operations management staff to duplicate. In addition, the operations staff had to access the system from more widespread locations, and this led to the need for an easier, more straightforward method to access information. Since operational information on Kibo will eventually span across ten years, it will exceed the volume of development information already available. There was now a critical need for a system which would allow users to visually, as well as intuitively, extract the data they need and this system would have to address and resolve all of these needs at once. JAXA thus proposed a 3D Search Interface applying Lattice Technology’s XVL format into the configuration parts tree and text search database that they were already using. (Shown in Figure 2.) The database system proposed evolved rapidly into the “Development and Operations Information Integration Database” system.

Figure 2. The 3D Search Interface

The most significant feature of the 3D search interface is its ability to display a selected part in its full form using a 3D model, and systematically obtain all related information on detailed parts. Information on Kibo’s parts is stored in the database, comprising attribute information on each part and 3D models in XVL. This information is also linked. In order to extract specific information needed from the enormous pool of information available, it is far more efficient to use visual 3D data to first narrow down the search, to identify a part, and to deliver related data on that part.

Figure 3 shows how the entire 3D Model of Kibo is displayed at the beginning of the search process. The user is able to visually identify the part or sub-assembly desired, and click this to display information on the part. In this way, the configuration parts tree of Kibo is linked to the 3D model. In other words, when one part of the configuration parts tree is clicked, the 3D model of the selected assembly or sub-assembly is displayed. By the selecting an individual part from the displayed assembly, the system displays the corresponding 3D data and related attribute information in ever increasing detail. Further details can also be searched as attribute information for each part.

There are high expectations being placed on the 3D Model Search system for Kibo’s operations across the next ten years. One application of the 3D Model Search, for instance, will be in detecting any system or equipment malfunctions, which are inevitable in the harsh environment experienced by the International Space Station. Any such problems need to be dealt with swiftly, and for this, ground operation staff need to be familiar with all the mechanisms of the space station - which itself is composed of an enormous number of parts. Once any problems are identified, the ground team has to be able to rapidly work out how to repair them, and then send the appropriate instructions to the astronauts. Since it is impossible for the ground operations staff to go on site, they will be using virtual 3D models. Figure 4.

The potential of this system is vast. For example, in space it is enormously complex and dangerous to inspect the exterior of the station. However, with 3D models, it is easy to see the exterior of the model and find the defects. To search for the location of an interior part is also easy in 3D: simply walk inside the virtual vessel! This feature is unique to 3D! For instance, in order to easily find components hidden by other parts, there is no need to remove the parts;- simply switch the display or make the 3D parts transparent. This support for ground staff will prove vital to the operations of Kibo in in space over the next 10 years.

To see the full story on JAXA and many other valuable case studies, research data and commentaries by Dr Toriya and leading manufacturers, click on the link below to register for the free download.

Click here to register for your free copy of "Improving Lean Manufacturing Through 3D Data" by Dr Hiroshi Toriya.