Manufacturing Process Optimization

Systematic improvement of production workflows using data-driven digital simulations and High-Performance Computing.

1. What is MPO?

MPO focuses on the "how" of vehicle production. It designs the production line and manufacturing techniques for maximum performance.

Cycle Time Reduction: Shrinking the time for stamping, welding, and painting.
Resource Efficiency: Minimizing energy, idle time, and scrap metal waste.
Predictive Quality: Identifying cracks or defects via simulation before casting dies.
Line Balancing: Harmonizing robotic speed and human ergonomics.

Digital Twins: HPC simulates the entire plant floor to predict global output changes.

Fluid Dynamics (CFD): Optimization of paint spray patterns to reduce expensive waste.

FEA for Stamping: Predicting sheet metal behavior during high-pressure forming.

Industry-standard CAE/CAM software requiring HPC for complex engineering calculations.

Category	Software / Apps	Usage in Automotive MPO
Plant Simulation	Siemens Tecnomatix Dassault DELMIA	Robotic path planning, floor layout, and human ergonomics simulation.
Fluid Dynamics (CFD)	Simcenter STAR-CCM+ Ansys Fluent	Optimizing paint dipping, spray atomization, and under-hood cooling.
Metal Forming	AutoForm ESI Pam-Stamp	Simulating sheet metal stamping to predict splits, wrinkles, and springback.
Crash Analysis	Ansys LS-DYNA Altair Radioss	Simulating impacts and deformations to define manufacturing tolerances.
CAM Machining	Open Mind hyperMILL	HPC strategies for 5-axis milling of engine blocks and precision molds.