Optimizing Automotive Press Line Tryout in Virtual Environment for Enhanced Intended Cycle Rate( ICR) and Production Efficiency

In automotive stamping, traditional robot programming and die tryouts during new vehicle launches consume substantial plant resources. Production plants must balance regular output with new product trials, creating bottlenecks and high costs in stamping lines. This research focuses on optimizing the Intended Cycle Rate (ICR) in tandem press lines using virtual technological environments, primarily Siemens' Technomatix software for simulation and validation. Multiple objective optimizations of robot paths minimize iterative tryout time and maximize production, while strategies such as early collision detection and tool design optimization are validated virtually. These findings offer actionable improvements in ROI by reducing launch process time and rework at production facilities. The methodology achieved up to 30% improvement in ICR through systematic bottleneck analysis and virtual commissioning approaches. Keywords: Press Line Tryout, Virtual Environment for Enhanced Intended Cycle Rate, Production Efficiency, ICR, Tandem Press line, Computer Aided Manufacturing, Stroke per Minute, Technomatix, CAD/CAM, Electronic Flow Chart and Press Line Simulation.