manufacturing Virtual at volvo cars manufacturing at volvo cars

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1 Dr.$Dan$Lämkull$ Volvo$Cars$Group$ Manufacturing$Engineering$ Virtual$Methods$&$IT$ $ $ digital digital factory factory and and Virtual manufacturing Virtual at volvo cars manufacturing at volvo Production Of Future Car Models cars How Simulation Is Used To Verify Flawless Far Before The Start Of Production How Simulation Is Used To Verify Flawless Production Of Future Car Models Far Before The Start Of Production 1

2 outlet Background virtual manufacturing at volvo cars history - today Tool set within virtual manufacturing engineering changing conditions and future challanges Layout, plant scanning and hybrid model Virtual verification of manual assembly tasks Verification in virtual environment using ips Virtual training of assembly workers 2

3 Background virtual manufacturing at volvo cars history - today 1984 Start with CATIA Robotics Advanced Engineering Production Evaluation: ROBCAD selected 1993 OLP Painting 100% 1997 OLP BiW Spotweld 100% 1999 FA is involved in Virtual Mfg 2006 Teamcenter Tecnomatix Catia V Assembly One Engineering instructions Environment in Teamcenter - OEE Scanning of of all plants all plants 3

4 Toolset - Manufacturing Engineering* Facility, Tooling and Equipment >800 *) Manufacturing Engineering approx people Within the Manufacturing Engineering organization there are Virtual Manufacturing Engineering (VME) groups in all areas: VME BiW VME Paint and Sealing VME Final Assembly Approx. 35 simulation engineers (FTE), 55 incl. consultants, in the European organization. 4

5 Ips application volvo cars approx. 250 uesrs Flexible Structure Simulation Assembly Path Planner Inspection Path Planner Robot Path Planner 6 Virtual Paint, Gluing, Sealing Virtual Luggage Packer IMMA

6 ips industrial path solution IPS is a math based tool for - automatic verification of assembly feasibility, - design of flexible components, - motion planning and optimization of multi-robot stations, - and simulation of key surface treatment processes. 6

7 Background: IPS from research to implementation IPS- Rigid Body first Continously developed and further improved in functionality IPS- Rigid Body is selected as simulation tool for assembly analyses IPS- Robotics - Sealing - Robot Balancing - Robot Cable - Painting/Gluing Continously developed and further improved in functionality in several research projects. IPS- Flexible is used for simulation of flexible materials IPS- 3.2 In November IPS 3.2 will be implemented. Including Point Cloud, Wiring Harness Editor, IPS-TC integration and IMMA Research projects Research project

8 Changing conditions and future challanges From To 2012 Engineering only in Sweden 2 flex. assembly plants 1 engine plant 1 stamping plant Volume ~400k vehicles/year 2016 Global Engineering (EU, China, Suppliers) 30% lead time reduction Limited physical builds 4 flex. assembly plants 2 engine plants 3 stamping plants ~ 600k vehicles/year x Engineering Output 50% lead time reduction > 4 flex. assembly plants > 2 engine plants > 3 stamping plants Volume 800k vehicles/year 8

9 scalable platform architecture But how? More models! shorter ttm/lead time Rapid follower! When your are small first within safety, environment and design around you 9

10 Sales volume [k] AUDI operating profit 2012 : 5 B spa scalable platform architechture X: number of products [year] 10

11 shorter ttm/lead time Leadtime from PS to J1: 20 months New XC90 36 months New S80 40 months Volvo S80 50 months Volvo months 11

12 shorter ttm/lead time from 36 to 20 mths Simulation is seen as one of the major enablers for reaching this vision We have to deal with all different simulation methods/areas related to manufacturing/manufacturing engineering: Flowsimulation / Discrete Event Simulation - DES Ergonomics Simulation Packaging analyses - nominal position, sequence analysis, clash detection OLP - Off Line Programming - robots, CMM, PLC Paint simulation - thickness analysis, sealing distribution, NVH application Layout analysis and MP&L

13 Optimal standard process Vision Vision BOP BOP Manufacturing Strategy Feedback On-the-shelf solutions Standard Standard BOP BOP BOP Requirements Requirements driven by BOP Plant Plant X BOP BOP Plant & Program specific Plant/Program Plant/Program Specific Specific BOP BOP Manufacturing Requirements (ME) Manufacturing Design Specifications (PD) Current status in Plant X at a given date in time Plant Solutions BOM / BOP compatability layout, scanning, manual assembly & operator training Line design" All products in sequence" Process/Operations" Tooling" Layout! Flowsimulation! Requirement Verification" Line/Station context! Mfg features" Balancing" Logistics" Annual & Pre-PS PS to J#1 Production Issue " Line/Stn KPI s - Scanning Offline changeover Geometry" Operator training! PLC" Robot" Ergonomics! TF1 + TF2" 13

14 Layout Layout is mostly 2D We have problems managing plant layouts over time Being a small manufacturer, the plant becomes complex since many product variants are going through the same plant We need layout in 3D and layout information easily distributed to all stakeholders over time 14

15 Layout - what do we have today? We have 2D layout, equipment models, and very good status on robot cells 15

16 Layout what do we miss today? We miss a plant structure with date effectivity (plant over time) It should be possible for any manufacturing engineer to get a layout over any plant at any given time It is desirable to have the layout in 3D from start and 2D as a viewer form Layout is more and more related to Plant scanning Layout is heavily related to flowsimulation 16

17 plant scanning and layout Laser scanned model built up of points and, if necessary, mixed with CAD models (Plant Hybrid Model) Each point has information of (X, Y, Z, R, G, B) position and colour The point cloud can easily be clustered as a component and treated as any CAD model 17

18 plant scanning and layout - Previous attempts Numerous attempts to make CAD models of the plants Our experience: Not working; Too time consuming The CAD models are not accurate enough - Not always 90 in corners - Not always parallel - Not always perfect plain Who to CAD for? What to include? Who will pay for the time? 18

19 Plant hybrid model - use cases Virtual Linewalks Operation Virtual Arena Area in the plant discussed during Virtual Build Event Date Created: November 14, Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group

20 Plant hybrid model - use cases Virtual Linewalks Body window studies 20

21 Plant hybrid model - use cases Virtual Linewalks Body window studies 2D layout validation 21

22 Plant hybrid model - use cases Virtual Linewalks Body window studies 2D layout validation Installation verifications Scanned Virtual model 22

23 Plant hybrid model - use cases Virtual Linewalks Body window studies 2d layout validation Installation verifications Plant visualization 23

24 Plant hybrid model - use cases Virtual Linewalks Body window studies 2d layout validation Installation verifications Plant visualization Visualize rebuilds 24

25 what do we miss in our simulations today? - The Plant Material Façade Line, working height Distance between cars on line - The holistic view - Product and product close equipments are included 25

26 What if 26

27 The point cloud is our digital plant Scan what we have! CAD what is new! Incremental scanning No conversion! Avoid reverse engineering! No objectification! Use Point Cloud As Is! 27

28 verify assembly case and logistics/layout 28

29 Virtual verification of manual assembly tasks Sofar most ergonomics simulations have been static analyses Most manikin software are closed and hard to integrate with and company specific standards or anthropometrics data are hard to integrate in the tools Volvo Cars is therefore developing an own manikin in a research project together with Volvo Trucks and Scania and Fraunhofer Chalmers Centre. The manikin is dynamic and finds a collision free assembly way, if there is any IMMA project (Intelligently Moving Manikin in Assembly) 29

30 Virtual verification of manual assembly tasks 30

31 Virtual verification - hand access studies 31

32 Virtual verification - tool access studies 32

33 Virtual verification - field of views 33

34 Virtual verification - working postures Examples of posture studies and suggestions for improvements 34

35 further research/development of the imma manikin More realistic look Collaboration with robots Realistic walk Company specific evaluation tools 35

36 more realistic look 36

37 Collaboration with robots 37

38 Realistic walk 38

39 Company specific evaluation tools Work condition 39

40 Verification in virtual environment using ips Simulating flexible materials in engine bay 40

41 Verification in virtual environment using ips Simulating Suspension Kinematics 41

42 Verification in virtual environment using ips 42

43 Virtual training of assembly workers (Virtual operator training / pcpt) PCPT is a virtual training application, and is a complement to traditional operator training In PCPT the operator can train on different work sequences: which part to assemble? what tool to use? where to perform the assembly? in which order shall the different parts be assembled? PCPT also enables the operator to train on different variants, e.g. variants with different engines or specific options. 43

44 Virtual Process Training PCPT is an interactive tool with four different levels of difficulty. Level 1 is the easiest and level 4 is the hardest. 44

45 Virtual Process Training If an operator makes a mistake in PCPT immediate feedback from the software will be provided. The operator can also ask for help Select&tool& Help Buttons Select&part& Show&where&part&& shoud&be&assembled& Reset&view& Show&& opera-on& text& Any mistakes made are presented in an overview after fulfilled sequence To be approved on a level, the operator must complete the whole sequence without mistakes 45

46 Difficulty&Level&1&& 1) Read&opera-on&text& Feedback&on&the& performed&training& 4) Click&on&highlighted&part& 5) Step&1;4&is&repeated&for&each& process&un-l&end&of&sequence& 2) Observe&which& tool&to&use& 3) Observe&part&number&and& descrip-on&(right&mouse&bujon)& 46

47 Virtual Process Training Complement to traditional training Especially we are training: - Sequence - Variants - Product knowledge Major benefits: - We can reduce the number of physical cars - Training time reduced by 40-60% - Independent on individual experts - Rather language neutral (pictures instead of text/speech) - More than 4000 employees have been trained during

48 volvo xc90 operator training example 48

49 example of virtual manufacturing within biw 49

50 We would like the Final Assembly area to reach the same maturity level as BiW when it comes to Virtual Manufacturing 50

51 A jump toward the future... 51

52 Thank you for your attention! Questions? 52