Virtual Reality in Assembly Simulations: Outpacing Tecnomatix Process Simulate for Faster Time-to-Market

Virtual Reality (VR) technology is emerging as a transformative solution in manufacturing industry. It offers significant advantages over traditional tools like Tecnomatix Process Simulate (PS) in assembly and ergonomic simulations. Analysis using PS is time consuming and lacks real time human interaction as it relies on detailed modelling and sequential workflows, which will delay the identification of assembly no-build conditions and ergonomic issues. This paper evaluates the time and cost saving potential of VR in assembly processes and explores its role in minimizing the need for physical prototypes across various stages of vehicle development. VR provides interactive environments, enabling interaction with 3D models and real-time collaboration with various teams across the globe. This leads to faster identification of assembly process flaws, quicker iteration cycles, and a reduced need for physical prototypes in the station development process for the lines. VR allows individuals to experience realistic simulations of assembly processes with multiple scenarios, without the risk of real-world safety consequences. This simulation approach through VR technology facilitates real-time ergonomics predictions, quick and accurate simulation of various assembly scenarios during the station development process before production with minimal iterations which will ensure the assembly processes are getting optimized in the early stages of the product development. It proves to be a superior alternative for validating assembly feasibility, reducing time in process sequence building, and achieving faster time-to-market in manufacturing. By minimizing iterations in physical prototyping and extensive validation and testing of assembly processes, VR significantly impacts time and cost. Keywords: Virtual Reality, Tecnomatix Process Simulate, Assembly simulation, Digital Manufacturing, Immersive Technology, Virtual Prototyping, Human-Centered Process optimization, Product Development