Posts Tagged Toyota

ISMAR09: Manufacturing Discussion

ISMAR09

ISMAR09 Sympsium & Expo is right around the corner and I’m pleased to announce that I’ll be not only attending ISMAR09, but I will be presenting during the Manufacturing section on Monday and joining the panel discussion as a representative of Toyota.  I’ll be reviewing the possibilities of augmented reality in an industrial setting, including a project that I’m working on with Metaio.  Hopefully I can enlighten participants on the constraints and challenges of implementing augmented reality on the factory floor. 

I’m announcing this on my blog, so if anyone has any requests for topics during the discussion, I can be sure to bring them up.  I was only able to confirm attendance last week, so there’s still plenty of time to update my presentation. 

Not only am I excited about presenting, but I’m more excited about getting to meet a lot of the people I’ve interacted with throughout the AR world.  I’ll be there from Sunday until Tuesday afternoon, so if you’re going to be there then, I’d love to meet up, chat and maybe, share a drink.

To reach me before or to contact me during the conferance, email me at tom.carpenter (@) tema.toyota.com or twitter to thomaskcarpente.  (Yes, the name is missing the ‘r’ since my name was too big for twitter.)  I’ll be tweeting updates during the conferance (as well, I use it regularly for posts and other augmented reality related news.)

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Will BMW Augmented Reality Glasses Really Work?

For some reason this augmented reality video from a couple of years ago is making the rounds again on various blogs and even Gizmondo is reporting it as fresh news.  Since its resurfaced, as a fellow car engineer for Toyota, I’ve decided to address some of the challenges to making a system like this really work.

 

1. AR Glasses

The first and obvious challenge is that the glasses aren’t yet a reality though they will be this year or next.   While a mechanic doesn’t care about style, the glasses still have to function well.  How fast of a refresh rate will the glasses need to not create “head lag” as the mechanic looks around in the engine.  The controls for the unit will also matter, since they’ll need to stop, start and rewind. 

2. Orientation

Without a paper marker, the glasses will need to orient the graphics onto physical locations on the car.  How well will they respond to dirty motors, poor lighting or the mechanic getting in the way of the camera?

3. Spatial Issues

When doing maintenance on parts that are easily accessible, augmented reality works well, but what about when the water pump under the wheel well needs replacement?  How well will augmented reality project the proper maintenance steps deep into the car engine space? 

4. Filling the Database

In the early nineties, our plant purchased a “wonderful” maintenance system that would house all of our PMs, keep track of all parts and what machines they went to and make sure we kept our machines in tip-top shape.  The flaw in this wonderful idea was that someone had to actually put all this data into the system and maintain its integrity as we upgraded machines and moved equipment around.  For high-frequency work, these AR maintenance glasses would be easy to develop, but who is going to make the other two hundred infrequent displays needed?

Overall, the promise of using augmented reality in industrial situations is quite large.  Given an improvement in the technology, I could find dozens of applications in my own plant.  Visualizing difficult tasks for team members using 3D data has huge potential, but it has to work right and be cheap enough to make it to the plant floor.  While I think AR will make its way into the production of cars (in fact, I’m working with Metaio on one such application) many issues need to be solved to make it a widespread usage.

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AR & Education

One of the most promising uses of augmented reality is in the field of education.  While some might think that using AR for education is just a gimmick designed to trick kids into learning, there is a scientific basis for why using visual information is important. 

Communication occurs through our senses.  We have five senses, but we don’t use them equally.  This is how we use them:

Visual – 75%

Hearing – 13%

Touch – 6%

Smell – 3%

Taste – 3%

As you see the sense we use the most, overwhelmingly so, is vision.  We get most of our information through the eyes. 

At Toyota, my employer, we put this into practice by requiring all papers to be condensed into one page.  We use lots of graphs, diagrams and as little words as possible.  We teach people to communicate through visualization, a prized skill in Toyota, because you can quickly convey a lot of information in a short time.  Even multi-million dollar projects are funded from one-page presentations given in less than five minutes.

This holds true for education.  So much is lost when a teacher stands at the board and lectures.   Little of the information gets through to the subjects, resulting in wasted time and uninterested students.  A recent post from Immersive Tech reminded me of the power of visualization.  While the video is from last November, it helps illustrate my words (yet again proving the point), so I’m reposting it.

 

I’m impressed by the interactivity of the molecular structure lessons, illustrating beautifully the complex nature of atoms with simple sweeps of the hand.  Seeing is believing and by seeing the lesson at a desk or on the projector, the students can stay engaged in the lessons. 

There’s a reason the phrase, “Do what I say and not what I do,”  exists.

We’re recognize the power of our actions outweighs the power of our words.

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The AR Hub

While I’ve only recently joined the AR conversation, Ori at Games Alfresco, and Rouli at Augmented Times, have been promoting AR for the last year.  Rouli announced this week they will be combining forces to help create a central clearinghouse for AR information.  And I for one welcome our new AR overlords

Seriously, I think this is a great idea.  A lot of AR content exists in various blogs, and I think the conversation between them could be enhanced by a site bringing them together.  Bravo guys, I’ll be happy to contribute. 

Lastly, Jan over at the Augmented Reality Blog, brought up that he would be giving us a little series about augmented reality in a production process.  I’ve had the pleasure of speaking to Jan about his company’s products for some projects at Toyota, and I’m looking forward to hearing more about his other ideas.

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AR for Industry

Today I had a nice phone conferance with Thomas and Jan from Metaio.  Jan is the author of the Augmented Reality Blog.  Jan had contacted me after reading my writeup about the use of AR in manufacturing based on a Microsoft video.  Thomas is one of their designers and has experience with automotive manufacturing.  And I’m looking for applications of AR to improve production at my Toyota casting plant. 

The basics of our discussion was how to apply AR concepts to a manufacturing enviroment.  The advantage I see for AR in a production enviroment is it brings complex levels of information to a real time enviroment.  Many of the challenges of running a factory is getting the right information to the right people to make the right decisions.  Every day people must make complex decisions, often with limited information, to perform their job.  We apply many systems to these operations to ensure we’re producing a quality product at a good price, but often times we waste efforts because everyone doesn’t have the information they need at the moment they need it. 

The combination of real time information in a production enviroment can reduce waste and improve quality if done correctly.  One example I can illustrate this example is with die repair.  We use steel dies for creating our castings and the dimensions of these dies need to be held tight tolerances of less than 0.20mm.  This means we must constantly repair our dies because of wear from the aluminum (aluminum is corrosive to steel). 

When we have to repair our die, we first have to weld it, then we machine it back to the required dimensions and then we check the quality.  If we make a mistake, we have to go back to the beginning and start over.  A common mistake is not putting enough weld material down, so when the weld is machined back to standard, gaps are created from the missing weld.  This picture illustrates the example:

welding

 

 

 

 

 

 

 

 

 

Using AR we can superimpose the correct dimension of the final shape over the worn die, so the welder knows if he’s put enough weld material on the die.  This gets the right information to the right person at the right time.  Before we had the right information, but we didn’t get it to the right person until much later in the process, so effort was wasted in between. 

This is one small example of using AR in a production enviroment.  And though we only had a brief discussion today about potential applications, my mind has been a-whirl about other possibilities, so I’m looking forward to working with Thomas and Jan to explore the potentials of this fledgling technology.

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More Philosophy for Entrepreneurs

Tim Ferriss on his popular Four Hour Work Week blog, had an interested guest post about the practical use of philosophy in business from Ryan Holiday.  Ryan focuses on the branch of philosophy called Stoicism.  I’m not going to further dissect his excellent analysis and application of the philosophy, but I would like to challenge his assertion that Stoicism is the only philosophy that has practical applications (I would also point out that Stoicism is similar to the Eastern philosophy of Taoism, best explained in The Tao of Pooh.) 

I would like to discuss the philosophies of Socrates in relation to Toyota. 

It’s no secret that one of the keys to Toyota’s success is its Toyota Production System.  In the United States, the Toyota Production System (TPS) tends to be dumbed down into lean manufacturing.  Lean manufacturing is akin to taking a martial arts class so you can beat up the guy down the street because he looked at your sister.  It gets you quick satisfaction, but doesn’t help grow you as a person. 

The TPS I want to talk about is rooted in The Toyota Way, which is a guiding philosophy of the company.  The aspects of the The Toyota Way I would like to talk about are the concepts of 5-Whys and the open mind.  The concept of 5-Why is that when presented with a problem, keeping asking the question “Why” until the true root cause is found.  Often times, the superior will ask his subordinate these questions when the superior feels that the subordinate hasn’t driven down to the real root cause.  This method is essentially, the Socratic Method

It is an important tool of any business because often times we’re busy solving the symptom of the problem and not the true root cause.  As an entrepreneur it can be even more important, because you don’t want to be bogged down making every decision for your employees.  By asking them questions, and letting them arrive at the correct conclusion (with proper feedback and positive encouragement), you can solve the problem and empower them.  As Tim states numerous times in 4HWW, you want to eliminate yourself from the process. 

The second, and most important philosophy that is similar between Toyota and Socrates, is the concept of the open mind or in the words of Socrates “I know that I know nothing“.  This concept most manifests itself during formal individual or group problem solving activities.  Leaders of a Jishuken activity (translates to “self-study”) are chosen by their willingness to have an open mind. 

The reason for emphasis placed on the open mind is a student who comes in with a predisposed mind will not succeed because they will be trapped by the limits of their knowledge.  One first has to admit that you know nothing (in a relative sense, we’re not asking to forget everything!) before you can truly approach the problem.  The open mind is sometimes developed through exercises such as an Ohno Circle or impossible tasks that force the student to look at things in new ways. 

I have found that the more knowledgeable members of Toyota are the most willing to say that they “do not know.”  I have heard Plant Managers and Managing Officers admit their not knowing.  They did not feel the need to “seem to know”, but were perfectly calm with their ignorance.  Then in doing so, they would ask many questions that would both inform the answerer and themselves. 

One of the highest levels of TPS thinking comes from the OMDD group within Toyota.  Students are put through rigorous training for two years and then are expected to return to their group and level up the thinking of those around them.  The most important trait that an OMDD candidate is expected to have is an open mind. 

While I do not know if the Toyoda family had read Socrates in their development of The Toyota Way, I am certain that if they didn’t; they arrived by the same willingness to examine everything with a critical eye, most importantly, themselves. 

“I know you won’t believe me, but the highest form of Human Excellence is to question oneself and others” — Socrates

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Toyota iQ AR Video

I’m almost embarrassed I haven’t seen this earlier, since I work for Toyota, but better late than never.  Not much to it, but it’s nice to see AR popping up in my neck of the woods.  The best part comes when they explode the car view to show all the parts. 

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