Plant Simulation as decision support Simon Lidberg

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Dulcie Lesley Lang
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1 Plant Simulation as decision support Simon Lidberg Agenda Introducing the company Discrete event simulation at Volvo Cars Why we work with simulation/optimization Simulation in projects Point cloud data Further developments

2 Some milestones and development Our Vision Our vision is to be the world s most progressive and desired premium car brand.

Our Journey 2011 - Transformation strategy initiated 2012 - New Product

product lines - Chengdu and Zhangjiakou operations started - V60 Plug-in

new XC90 launch - China biggest market - US focus - Connected services

- New C-segment modular platform - Autonomous Drive/Drive Me LONG TERM

2014 3,1% Japan Other markets 24,3% 3,2% Italy 3,5% Russia 3,6%

3 Our Journey Transformation strategy initiated New Product Strategy Profitability - China volumes take off - Renewal of major product lines - Chengdu and Zhangjiakou operations started - V60 Plug-in Hybrid launched - New design direction - Drive-E Powertrains All new XC90 launch - China biggest market - US focus - Connected services launch New products on Scalable Product Architecture (SPA) New C-segment modular platform - Autonomous Drive/Drive Me LONG TERM GOAL - 800,000/year - Reduce project lead time by half Top Ten Markets ,1% Japan Other markets 24,3% 3,2% Italy 3,5% Russia 3,6% Netherlands 4% Belgium 6,8% Germany Retail sales *Jan-Jun 2014 UK China Sweden 13,3% USA 8,6% 16,8% 12,8%

4 Our engines 4-cylinder petrol VEA 5-cylinder petrol 5-cylinder diesel 4-cylinder diesel VEA Getting the power out of a 4 cylinder Engine T6 D5 T5 T4 T3 D4 D3 D2

The Value of DES in projects A continuously updated

We check our own and our suppliers thesis and

We can find near optimal settings for our systems.

upon. Why work with simulation / optimization?

DES can provide invaluable answers that s impossible to

DES can support or discard ideas, concepts, theories or

5 The Value of DES in projects A continuously updated visual model of the system we want to build. We check our own and our suppliers thesis and calculations about the system. We can find near optimal settings for our systems. Ability to identify and continuously follow up constraints in the system. All with the goal of knowledge to base our decisions upon. Why work with simulation / optimization? Is now mandatory in our projects at Volvo Cars. DES can provide invaluable answers that s impossible to get from traditional methods. DES can support or discard ideas, concepts, theories or statically calculated decision bases. The DES model will define the system to the supplier. High Quality Decisions Knowledge Simulation, optimization and knowledge extraction Data and Objectives

Multi-objective Optimization Ability to make the contextually most optimal decision based on several objectives.

- Templates with automatic import/export functions. Teamcenter support.

Takes time to build complex models. - Standard library with objects to lower build time and increase familiarity.

6 Multi-objective Optimization Ability to make the contextually most optimal decision based on several objectives. DES Disadvantages and their countermeasures A complex model needs a lot of data and it takes time to update it. - Templates with automatic import/export functions. Teamcenter support. Extensive knowledge is needed in order to simulate complex systems. - A group that works full time with flow simulation. Takes time to build complex models. - Standard library with objects to lower build time and increase familiarity. Complex models need alot of time to run. - Computer cluster to run experiments and optimizations. Low quality input data. - Work is underway to install a new manufacturing execution system that can supply high quality data.

7 Example projects Area New cylinder block line New crankshaft factory Cylinder block line Internal assembly Whole Skövde plant Total assembly flow China engine plant Evalute production planning strategies Answers to Conceptual layouts (blue sky), capacity differences between double spindle and single spindle machines. Capacity/limitations from 3 gantry suppliers. Identify bottlenecks. No. of palettes. No. of AGVs, Buffer sizes (for queues and stores). Capacity for the whole flow. Reduced size of inventory. Future development Develop our standard library. Further development of Teamcenter support. Virtual Commissioning. Simulate operator requirements. Simulate product cost. Simulate energy requirements. Expand our computer cluster. Expand the cooperation in VCC and with other companies. All with the aim towards the state where the virtual factory is the original and the reality is a copy.

Hybrid models DES models incorporated with point cloud data. Work ongoing to scan all our lines. Aids in visual verification of models. Further benefits for other type of simulations.

8 Hybrid models DES models incorporated with point cloud data. Work ongoing to scan all our lines. Aids in visual verification of models. Further benefits for other type of simulations TECNOMATIX PLANT SIMULATION WORLDWIDE USER CONFERENCE 2015, PLANT SIMULATION AS DECISION SUPPORT INSTRUMENT AT VOLVO CARS, 15 SIMON LIDBERG Whole factory model Skövde engine plant TECNOMATIX PLANT SIMULATION WORLDWIDE USER CONFERENCE 2015, PLANT SIMULATION AS DECISION SUPPORT INSTRUMENT AT VOLVO CARS, 16 SIMON LIDBERG

9 Summary Using DES models is required at Volvo Cars. Used in all levels, from production to management. Move from gut feeling to decisions based on knowledge. Reduce DES project lead time by standardizing objects. Quick answers to our project leaders TECNOMATIX PLANT SIMULATION WORLDWIDE USER CONFERENCE 2015, PLANT SIMULATION AS DECISION SUPPORT INSTRUMENT AT VOLVO CARS, 17 SIMON LIDBERG

VOLVO CARS CORPORATION Presentation at BrandMaker Conference in Cologne May 15 Anna Vilhelmsson and Elena Borrego

VOLVO CARS CORPORATION Presentation at BrandMaker Conference in Cologne May 15 Anna Vilhelmsson and Elena Borrego AGENDA 1. Presentation of the company 2. Introduction to the Volvo Cars Content Store 3.