Optimizing and designing production lines
Digital Manufacturing FJGP4D
Smart Factory Fujitsu software designed for customers in the manufacturing industry
Digital Manufacturing FJGP4D is a powerful production support tool for visualizing process design that enables effective process design and various kinds of evaluation in the field of assembly and logistics.
FJGP4D realizes optimization and consensus building through process design and various verifications in virtual space using product CAD data, sequence data, and equipment data converted with FJGP4DSGS (the FJGP4D Manufacturing CAD data conversion application). It also assists efficient preparation for production through the utilization of the resulting output in preparation for production and mass production line development.
FJGP4D enables to:
- see both the flow of the products and the traffic of the workers virtually at the same time;
- create at the production preparation stage a virtual production line and run simulations on factors including the most efficient movements or positions of production workers, the optimal alignment of workers in relation to the flow of a production line, and the time required to complete specific production tasks;
- reach greater efficiency in assembly work on a production line from the standpoint of people;
- benchmark staff work against the simulation results;
- share understanding of problem areas with co-workers, leading to improvements on the front lines of assembly plants.
How FJGP4D works?
Benefits
Launch global mass production efficiently and reduce costs
Calculate productivity quantitatively and determine the best plan without running actual trials
Realize “Kaizen” and high productivity without stopping the current line
Develops multiple models for 3D line plans made during the planning stage
Production line optimization through simulations of the movements of production line workers
With FJGP4D, users are able to simulate the most efficient movements or positions of production workers, as well as the optimal alignment of workers, by configuring the basic movements of production workers (such as patterns of walking or patterns of hand or arm movements) in the designed virtual production line. The time required to complete specific production tasks can also be automatically calculated. Through mathematical modelling, evaluation, and analysis of the workers, end product, and machinery, FJGP4D will enable the realization of the optimal production line.
Evaluation and verification of assembly processes from the dual perspectives of end product and people when combined with Fujitsu's FJVPS
By using FJGP4D in conjunction with Fujitsu’s virtual product simulator (FJVPS), a 3D virtual verification simulation tool for verifying product assembly processes, users are able to verify the optimization of assembly processes from the dual perspectives of both the end product and the workers on the assembly line.
User-friendly operation
Skill and training are required to effectively use CAD, but FJGP4 is very user-friendly enabling first-time users who have never used simulation software to employ it with ease. Use of virtual equipment enables quick design of virtual line. Designs of the virtual production line used in the simulation can be completed quickly by using different types of virtual equipment templates built-in to the software.
Capabilities
Import of 2D-cad data or image files as a sketch
Import 3D-cad data of facilities and equipment
Generation of the movement of operators and the flow of materials without any programming
Visualization of process balances and productivity by operator balance chart that is automatically generated
Evaluation of quantitative productivity that are value and non-value added works, and workability such as working postures and walking distances
Generation of operator’s walking routes that avoid obstacles automatically
Case Study
Sohbi Craft Poland Co. Ltd.
Lean Management in Practical Application of Simulation Tools
(Manufacture of automotive parts and precision equipment, mold design and construction, unit assembly, etc.)
Sohbi Craft Poland Sp. z o. o. (Sohbi) was convinced that simulation tools could fundamentally change how they design their production lines. An encounter with FJGP4D (‘GP4’) led them down the path of digital transformation and their approach to production line design and modification has evolved in unexpected ways.
Benefits of simulations
- With the help of GP4 is was possible to simulate and test lines where either robots or a line pacer (transfer) device were used to move products between presses.
- The Taiwanese supplier was able to design the equipment as expected thanks to video sharing of simulation data
Production line planning consultation for external companies
Sohbi is commissioned by such companies to design automated production lines, create robot programs, and perform maintenance work. By utilizing simulation tools, the company is able to freely consider multiple line layouts and study in-plant logistics. As a result, the Sohbi is highly appreciated by its clients. The introduction of GP4 has not only revolutionized the traditional design and development process, but has also helped establish a new business model based on simulation technology.
Future DevelopmentSohbi has been utilizing GP4 simulations in their own and their customers’ production lines in a variety of scenarios, including
- New production line design
- Work planning
- Various production line tests
- New solution design/application of latest technology
- Continuous improvement
- Lean training
- Marketing
Learn More
How to make FJGP4D data?
FJGP4D requires CAD data. Once input CAD data into Process-BOM, FJGP4D forecast automatically worker behavior, posture and machine operation and show real-time 3D execution. FJGP4D also estimate process balance and specification of process plan into table list.
CAD data as virtual product
- Major CAD data will be converted
CATIA, Pro-engineer, SolidWorks, etc.
Original equipment library for factory
- Over 500 library are provided from LEXER
- Parametric modification will makes them fit to customers original factory plan
Assembling order data
- Import from EXCEL
- Generate form product structure
- Drag & drop operation in FJGP4D
Basic Operations
In FJGP4D, the available operations vary depending on the mode. The key to accessible operations is the mode to select.
Sequence
- Sequence Edit Function
- Sequence Execution Function
- Yamazumi
- Mixed-flow
Process
Line
Factory
Element
Modules
- Four Applications of FJGP4D
GP4VMS
Operates the production site defined in the virtual space to evaluate a daily volume and part supply timing.
- Four Applications of FJGP4D
GP4PES
Operates the production site defined in the virtual space to evaluate a daily volume and part supply timing.
- Four Applications of FJGP4D
GP4SGS
A tool to import VRML files exported from CAD, edit product part structures, and convert the format for GP4VMS.
- Four Applications of FJGP4D
GP4SES
A tool to modify size, angle, origin point, material, and texture of existing shapes, merge multiple shapes, and create simple geometric shapes.
- Add-ins for GP4VMS
GP4RES
Displays the results of various simulations using GP4VMS as assessment values by process on the Evaluation Table. Also displays the Project Table to weigh up multiple plans of layouts and operation sequences.
- Add-ins for GP4VMS
GP4WFS
A tool to convert the existing operation instructions to GP4 format, and load operation sequence information into GP4VMS. After the loading, ideal time can be calculated from “operation time with incidental” to apply.
General purpose element
Elements with 3D shapes used for GP4VMS: Standard shapes such as boxes, pillars, and spheres; Production equipment such as tools, shelves, logistics equipment; Factory equipment such as walls, shutters, cranes; General parts such as nuts and bolts.
Character element
Operator elements between 140 cm and 190 cm in height. The posture value assessing work posture is set based on 3D strike zone definition.
Product Requirements
Operating System | Microsoft Windows 11 (Pro, Enterprise) |
CPU | 1GHz and above *2 |
Physical memory (RAM) | 2GB and above (4 GB and above is recommended) *2 |
Hard disk capacity | 1GB and above |
Graphics card | memory 128MB and above |
Software | Microsoft Excel is required for document output. *4 |
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Why Fujitsu?
Fujitsu is a manufacturer that designs and manufactures products on its own, including supercomputers, servers, telecommunications equipment, and mobile devices. Based on its experience in manufacturing, Fujitsu provides PLM package software solutions:
- 3D Design/ Modeling
- Virtual Assembly and Process Simulation
- 3D Visualization in VR
- Optimizing and Designing Production Lines
- Motion Analysis Software
Based on 30 years of experience in the industry, Fujitsu provides package software that caters to customers’ needs.
By developing its own package software, Fujitsu maintains high product quality to meet customers’ needs.
Fujitsu is capable of providing customers with a full range of services, including hardware (e.g., PCs and servers) as well as networks, telecommunications equipment, and software.
As an SI vendor, Fujitsu has helped many customers construct business operation systems for many years.
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