Ford Developing Virtual Factory to Hone Production Process

FordFordUnited States of America, 1903 > present92 models
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is developing a virtual factory where it can hone its production process for future vehicles before they ever are physically produced. Ford says that this will allow it to cut costs and improve quality. Ford thinks that it will have the technology ready to apply to actual vehicles in the near future. 

“We have already started work on our virtual factory project, so that we won't have to go to the real assembly line to conduct tests or research possible plant upgrades,” said Ford engineer José Terrades.

Modern computer production and computer-aided design make this technology possible. Every piece of Ford's cars already exist has a CAD file that can be loaded into the virtual factory. The virtual factory allows Ford to know exactly how much it will cost and how much time it will take to manufacturer each part. It can even simulate the processes that workers will go through to build each part. 

For the actual factories, Ford goes in to photograph and scan everything. Then it can load the factory into the virtual factory. Ford's Valencia, Spain, factory is leading the transition and will likely be the first factory that Ford can simulate as a virtual factory. 

When using the virtual factory, Ford's engineers use special projectors and motion-sensing 3D glasses to create a virtual reality environment. 

Ford's update to its Cologne design center included a virtual reality vehicle projection center. It allows Ford to project interiors in 3D and for designers to interact with them in virtual reality.