Digital manufacturing is the use of integrated computer systems for simultaneous product and manufacturing process definition using simulation, 3D visualization, analytics and collaboration tools. It evolved from initiatives highlighting the need for collaborative design. Digital manufacturing enables information exchange between design and manufacturing and helps companies achieve goals through reduced downstream changes. It allows creation of complete virtual manufacturing processes for optimization before production. Current developments aim to improve the user experience and provide direct shop floor connectivity.

1. Digital Manufacturing
Digital manufacturing is the use of an integrated, computer-based system comprised of
simulation, three-dimensional (3D) visualization, analytics and various collaboration tools to
create product and manufacturing process definitions simultaneously. Digital manufacturing
evolved from manufacturing initiatives such as design for manufacturability (DFM),
computer-integrated manufacturing (CIM), flexible manufacturing, lean manufacturing and
others that highlight the need for more collaborative product and process design.
Many of the long-term benefits from product lifecycle management (PLM) cannot be
achieved without a comprehensive digital manufacturing strategy. Digital manufacturing is a
key point of integration between PLM and various shop floor applications and equipment,
enabling the exchange of product-related information between design and manufacturing
groups. This alignment allows manufacturing companies to achieve their time-to-market and
volume goals, as well as realize cost savings by reducing expensive downstream changes.
Digital manufacturing systems allow manufacturing engineers to create the complete
definition of a manufacturing process in a virtual environment, including:
• Tooling
• Assembly Lines
• Work Centers
• Facility Layout
• Ergonomics
• Resources
Simulation of production processes can be performed, with the intent to re-use existing
knowledge and optimize processes before products are manufactured. Digital manufacturing
also allows feedback from actual production operations to be incorporated into the product
design process, allowing companies to take advantage of shop floor realities during the
planning stage.
Current initiatives in the development of digital manufacturing tools involve improving the
user experience, so that information is presented in the context of tasks performed, allowing
users to make better decisions faster. Steps are being taken to provide direct connectivity with
shop floor hardware, such as programmable logic controllers (PLCs), machine controllers,
computer numerically controlled (CNC) machines and others. Unified platforms have
also been developed to manage both PLM and manufacturing execution system (MES)
information.
Examples of Digital Manufacturing Applications

2. Digital manufacturing is utilized in a variety of industries. An automotive original equipment
manufacturer (OEM) can design the entire manufacturing process digitally (tooling,
machining, assembly sequencing, and factory layout) at the same time that designers are
designing the next vehicle program. Because of this, manufacturing engineers are able to
provide immediate feedback to designers, if there are any constraints in the part
manufacturability. This type of collaboration between manufacturing engineers and designers
creates a holistic view of product and process design.
A high tech supplier can use a digital manufacturing system to create a 3D simulation of a
complete production line, and analyze the different production variants and concepts as part
of the request for quote (RFQ) process. This kind of transparency and precision in planning
and proposal preparation can help this company to gain greater customer confidence, and
ultimately help it win the contract.
Benefits of Digital Manufacturing
Digital manufacturing can help manufacturing companies improve their productivity in both
manufacturing planning and production processes.
• Digital manufacturing enables product, process, plant and resource information to be
associated, viewed and taken through change processes, with a consistent and
comprehensive approach to production design.
• Digital manufacturing allows part manufacturing processes to be optimized within a
managed environment. You can produce flexible work instructions capable of
displaying 2D/3D part information, along with the machining and tooling instructions.
• The simulation capabilities of digital manufacturing help reduce commissioning costs
by validating robotics and automation programs virtually.
• Using digital manufacturing, you can create factory models faster and ensure that they
are operating under optimal layout, material flow and throughput before production
ramp-up.
• Digital manufacturing can be used to support six-sigma and lean initiatives, by
providing a graphical environment to analyze dimensional variation.
• Digital manufacturing systems facilitate the sharing quality data across your
organization by generating complete, verifiable CAD-based machine inspection
programs for coordinate measuring machines (CMMs) and numerical control (NC)
machine tools.
• Digital manufacturing allows you to execute production processes with real-time
access to lifecycle data.