Virtual Build: Low-Tech Simulations Can Be High on IPPD Content

After two years of design, component testing, and parts fabrication, the project team was within months of starting assembly on the first major elements of a new product assembly. Schedules were extremely tight and there was no room for error in the first unit build-up for test. The first draft of the assembly drawing was nearing completion and needed to be approved by key members of the Integrated Product Team (IPT) before release. Only then could the manufacturing planning be finalized and released for assembly to begin. What could we do to improve the quality of our first build effort? How could we minimize all the changes inherent in the first-time build of a complex mechanical system? Why not a dress rehearsal of the build process with all the participating players, hardware, and build documentation? A "virtual build simulation". In an organization employing integrated product teams there is no substitute for clear communication between the various cross-functional members. Despite team collocation, integrated solid modeling, and frequent coordination meetings. elements of the product-process design can still slip through the cracks and show up on the assembly floor. The virtual build exercise was designed to provide one intensive hands-on experience for all members of the design and assembly team in time to make corrections without schedule impact.