Roadmap to Create Digital Twin of Car Plastic Exterior Parts with Injection Moulding:

1. Define Project Scope:

   • Identify the specific plastic exterior parts to be manufactured using injection moulding.
   • Determine the number and types of connected halls required for the production process.
   • Specify the desired capacity and production targets.

2. Design the Layout:

   • Create a layout plan for the connected halls, considering the flow of materials and products.
   • Allocate space for the robotic paintshop line, automatic and traditional warehouses, buffers, quality check areas, and assembly lines.
   • Ensure proper integration of JIS (Just-in-Sequence) and JIT (Just-in-Time) lines, both traditional and robotic.

3. Material Flow Simulation:

   • Utilize process simulation software to model the material streams from granulate to the dryers.
   • Simulate the pneumatic transport of granulate to the injection moulding machines.
   • Analyze different scenarios for material flow, including direct transfer to the paintshop line or buffers.

4. Injection Moulding Process:

   • Select suitable injection moulding machines based on required capacity and technology.
   • Install the machines in the connected halls, considering the material flow simulation results.
   • Connect the machines to the material supply system, ensuring seamless granulate transport.

5. Paintshop Line Integration:

   • Install the robotic paintshop line, considering the required capacity and paint application technology.
   • Connect the paintshop line to the buffers or directly to the injection moulding machines.
   • Implement quality gates within the paintshop line to ensure proper painting and surface finish.

6. Warehouse and Buffer Setup:

   • Establish automatic and traditional warehouses for storing both painted and non-painted exterior parts.
   • Determine the storage capacity and implement an efficient inventory management system.
   • Integrate buffers between different stages of the production process to balance the flow of parts.

7. Quality Check Areas:

   • Design and set up quality check areas at critical stages of the production process.
   • Implement automated inspection systems, including vision systems and quality control equipment.
   • Ensure proper documentation and traceability of quality checks for each part.

8. Assembly Lines:

   • Establish assembly lines for the final integration of plastic exterior parts into the car.
   • Determine the required capacity and layout of the assembly lines.
   • Integrate JIS and JIT principles to ensure timely delivery of parts to the assembly stations.

9. Packaging and Expedition:

   • Define packaging requirements for the finished plastic exterior parts.
   • Implement an efficient packaging process, considering the specific part dimensions and protection needs.
   • Establish a streamlined expedition process, ensuring proper loading onto semi-trucks ramps.

10. Digital Twin Implementation:

    • Collect data from sensors and machines throughout the production process.
    • Integrate the collected data into a digital twin platform, enabling real-time monitoring and analysis.
    • Utilize advanced analytics and machine learning algorithms to optimize the production process and identify potential improvements.

11. Industry 4.0 Integration:

    • Implement connectivity and communication protocols between machines, sensors, and the digital twin platform.
    • Enable remote monitoring and control of the production process.
    • Explore opportunities for predictive maintenance and autonomous decision-making based on the digital twin insights.

12. Continuous Improvement:

    • Regularly analyze the data collected from the digital twin to identify bottlenecks and areas for improvement.
    • Implement changes and optimizations based on the insights gained from the digital twin platform.
    • Continuously monitor and refine the production process to achieve higher efficiency and quality standards.