migration manufacturing - polimi.it

1Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Migration Manufacturing©

A New Approach for Automotive Factory Planning

Dr.-Ing. M.S.M. Thomas P. MeichsnerExecutive Director

Production Technology, Press Shops, Specialty CarsWilhelm Karmann GmbH, Osnabrück

2Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Karmann –more than 3,3 million cars produced since 1949

3Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Global Locations

AGS GmbH,OsnabrückLogistic Services

Karmann U.S.A., Inc.Plymouth, MichiganTechnical DevelopmentPrototypesRoof Systems

Karmann-Ghia do BrasilSão Bernardo do CampoProduction TechnologyStampingVehicle Manufacturing

Karmann-Ghia de Mexico, PueblaRoof System Production

Karmann-Ghia de Portugal Vendas NovasSeat Cover Production

Karmann SunderlandU.K.Roof System Production

Karmann JapanYokohamaSalesEngineering

AKC Componentes automotivosResendeProduction Technology

Karmann ZaryPolenRoof System Production

Karmann ChorzówPolenTooling

Wilhelm Karmann GermanyHeadquarters: OsnabrückVehicle Engineering, Production Technology,Roof Systems, Vehicle Production

Karmann Engineering Services GmbH,BissendorfEngineering

4Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Powertrain & Chassis Integration

PrototypesVehicleTesting

Engineering/Concept

MachiningTools & DiesBIW AssemblySystems

QA Tooling Stamping Paint Shop Final Assembly

Module Manufacturing

Body-in-White

Styling Concepts/Advanced

Engineering

Package/MeasureConcept/

Surface Class A

Design/ Engineering

PlasticsTechnology

RoofSystems

FEM Analysis

Soft-topProduction

Full Service Supplier

5Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Selected Reference Projects…

A6 Scania

Audi Cabrio A3 Sportback Vaneo

Megane

SLK

MAN

Sprinter Bentley

Crossfire

CLK

6Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.051SW

Limousine

Station Wagon

Flow Tail

Off-Road

Coupé

Cabrio/Roadster

70er

Limousine

Coupé

Cabrio/Roadster

60er

Off-Road

MPV

Limousine

Station Wagon

Flow Tail

Coupé

Cabrio/Roadster

80er

MPV

SUV

Compact-MPV

Off-Road

Limousine

Station Wagon

Flow Tail

Coupé

Cabrio/Roadster

90er

MPV

SUV

Compact-MPV

Off-Road

Limousine

Station Wagon

Flow Tail

Coupé

Cabrio/Roadster

Cabrio Coupé

Coupé-Limousine

Tall Wagon

2005 - 2010

Sports Tourer

SAV

…

Market Development Niche Vehicles

[Polk Studie 2006]

7Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.065SW

Market Development –Example Compact SUV

1999 2001 2002 2003 2004 2005 2006 2000

5000

10.000

15.000

20.000

0

21.00019.800

19.000

15.500

9300

14.500

10.500

85008000770075006500

MercedesML

ToyotaRAV 4

HondaCR-V

NissanX-Trail

BMWX5

BMWX3

VWTouareg

HyundaiTucsow

HyundaiSanta Fe

AudiQ7

[Units/year]

year

[Autobild]

8Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.053SW

Platform

Platform Strategy

9Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.105SW

Roof Frame

Roof

III. Body-in-WhiteFrame

Rear section

Main Floor

Front Section

Floor

Production Steps

I. Underfloor

Basis: Limousine

Example: Cabrio Variant

Side Panel

Side Panel

II. Underfloor withSide Panels

Closures

Doors

Fender

Hood

IV. Body-in-White

Assembly Sequence Body-in-White Platform Strategy

10Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.066SW

Component

Productlevel

Station System

Product

Part

Feature

Section Plant Network

Portfolio

Productionlevel

Agility

Changeability

Flexibility

Reconfiguration

Umrüstbar-keit

Re-tooling

Changeability Typs of Production Plants

11Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.067SW

Productlevel

Station System

Assemblies

Underfloorgroups

Plant

Body-in-White

Productionlevel

Body-in-White

Assembly

Komponenten

Floor Assembly Roof Hatches

•• • •• •

Robots, Welding guns,Tension sequences•• •

Levels of the Body-in-White

12Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.054SW

SOP: Start of Production; EOP: End of Production

SOP EOP

Units

Start EndProduction

Svolatil

Sspread

Start-upangle

Ω

α

Speak

Slevel

SAverage

SEnd

Reference Life-Cycle Curve and Requirements of amigrating Body Shop

Requirements

•Reduction of

investment >30%

•Multi-Model-Ability

min. 3 models

•Scalability ± 30%

•Smooth integration

of new models

•High degree of

re-integration

•Quick return of

capital

Reference Curve Volume Development

Time

End ofproduction angle

13Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.070ASW

Modularity

Changeability Typs

Compati-bility

Mobility

Universality

AB

C

Scalability

Typ

Variant

Flexibility Typs

Re-Integration

Process

Volume

Part

MigrationPrinciple

Multi-Model andScalable

Production Volume

FlexibleFramingStation

GeoHandling •• •

Requirements and Targets for theMigration Concept in the Body-in-White Production

14Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Flexibility through Movability

[BMW]

15Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Re-Use of Production Equipment

Plant and Equipment Layouts

A209

The re-use of production equipment is in principle possible. However change-over strategies and adaptation is difficult and often not possible. After end of production (EOP) the integration of a new model is possible.

Therefore EOP and SOP are directly related to each other.

EOP 12/07

EOP 09/09

16Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Production LayoutBody-in-White Production (Example)

[BMW]

17Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Framing Station

An expansion of the line ist hardly possible.

18Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.094SW

Characteristic• Stable sales•Low flexibility• No variants

Focus: Line tact

Example•E-Class (old)

Solitude Principle

Production for oneBody-In-White-Model

Volume

Time

Vmax

Start Productionphase

End

Migration Principle

Production for many Modelswith additional Variants each

Characteristic• Life Style Sales•Different B-I-W/

Models•No common platform•Production equipment canfollow demand on short termin

Focus: Moveable, scalablework contents

Example•Karmann

ModelsV1

V2

V3 A

B

C

Volume

Time

Flexible Principle

Production for many Body-in-White Variants of on Model

Characteristic• Dynamic sales•Compensation of volumeChanges through additionalB-I-W Variants

•Flexibitlity only with sameplatform

Focus: Line balancing

Example•Audi A3

Coupé

Limousine

Station WagonCabrio

S S S EndStart

Volume

Time

VmaxVariants

Manufacturing Principles of the Body-in-White Production

19Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.059ASW

Principle

Structure

Sub-Systems

Specific ChangeabilityEnablers

Special FlexiblityTypes

Migration Concept

Structure of the Migration Concept

20Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.205SW

Technology ControlInfrastructure

Human Resources

Sturcture of the Concept

Types of Flexibility

Logistic

Scalability CompatabilityModularityMobilityUniversality

Versatile

Product Mix Successor Volume Space

Solutions for the Concept Structure

21Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.118SW

Tg : Type-related

Tu : Type-unrelated

Jigs and Fixtures

(Tg)Rotary Fixture

(Tu)

Welding Gun (Tu)

Robot

Turn Table

Storage

Safety Fance and Equipment (Tu)

ControlerNetwork (Tu)

(Tg)(Tu)

(Tu)

(Tu)

(Tu)

Type-Related and Type-Unrelated Componentsand Sub-Systems

22Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.078SW

M

Geometry Welding Special Tasks

Content:• Jigs and Fixtures• Robots• Gripper Technology• Welding Gunswith/without changing

•Robots•Welding Gunswith/without changing

•Measurement Technology•Touch and Pierce•Assembly Technology•Laser Technology

Invest-relation:

100%(Basis)

20% up to 200%

Types of Production Cells

23Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.097SW

HandlingLocation and

Clamp SystemsJoining Technology Forming and

ProcessingTransport andBuffer Sytems

ControlSystems

PeripheralSystems

Examples•Grippers- Geometrical

gripper- Multi-functional

gripper- Sorting gripper- Modular gripper

•Robot used asa manipulator

- stationary- mobile

Type-Specifitylow

Re-usablitygood

•Clamp systems(LCS)

- flexible LCS- adaptive LCS- modular LCS- dynamic LCS

high

middle

•Welding- Spot welding- MIG welding- MAG welding- WIG welding• Laser welding• Riveting• Bolting• Adhesive

low - middle

good

•Soft touch formand pierce

•Hemming- Roller hemming-Table top

hemmer•Milling•Drilling•Piercing•Parting

high

middle

•Portal systems•Mobile Systems•Conveyor systems•Stationary buffers•Combined

Buffer / Conveyorsystems

•Loading stationfor material

• Unloading station- manual- automatic

low

middle

•Networks- LAN- WAN•Control•Regulate•Measure

middle

good

•Safety and protectivesystems

•Media•Identification

systems (RFID)

low

good

Body in White System Components (Examples)

24Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.116SW

Robot

Hemmingfixture

Layout 1

Doorfront/left

Doorfront/right

Doorrear/right

Doorrear/left

Door front/right

Door rear/right

Layout 2

Door front/left

Door rear/left

Capacity Increase of Roller Hemming Cell (Example)

25Migration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

14.088SW

AlternativesMultiplication Network

BasisChanging element

Structure

Parallel Sequencial

Station

Sub-SystemMultiplication Extension of Motion

ComponentsMagazine Magazine

AB

Sub-ComponentsExchange Adaption

RoutingRepeatition

2xRe-routing

Work Contents

Doublication Separation

Sourcing?

external Internal

Purchase (external) Addition (internal)

A

Technical Changeability Concept of the Core Competenceof the Migration Principle

26Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Reduction of the Production Equipmentfor a Front and Rear Closure

14.227SW

R1

R2

Modular fixtures

R1

R2 Roller hemming bedexchangeable

27Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.226SW

Modular Equipment for the Productionof Front and Rear Closures

28Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.203SW

Direction of the migration

Model A

Phase 1 Phase 2

Model A Model B

Core production line

Growth sectionof the equipment

New coreproduction line

Migration Path from outer to inner

29Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Migration Concept on 3 Levels

14.122SW

Plant level

Line level

Cell level

30Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.112SW

Migration on Plant Level

Plant 1

Capacity

Plant 2

Capacity

100%

body-in-white paint assembly

100%

body-in-white paint assembly

31Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.086SW

a) Layout b) Volume Development

e.g. Wedding-Line

Base

AdiitionalTransport-Systems

Time

Volume

Transport-net

Step 1

Step 2

Step N

Additional Cells

e.g. Geo-Cell

Layout Concept Chess

32Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.084SW

a) Layout b) Volume Development

Base

Step 1

Step 2

Additions toWelding Line

Zeit

Volume

Step 2Welding Line

Welding LineStep 1

Main Geometric Line

Base Line

Layout Concept Meander

Characteristics: tact-free definition, free choice of cells, scalable, defined growth parths

33Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

mögliche Platzierung der Fertigung Boden vst. (Layout lt. Anfrage)

Dach

RespotMAG

Respot

Produktions-

szenario

EHB

Rollenbahn mit Skid

Lift

Geo 2Geo 1

Inline

Respot

Layoutvariante:

§ solitär, Neuanlagen

§ Brownfield, Hallen Shedbau

§ 16,6 EH / h

Mäander Layout –One Car Model

34Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

§ Integration von:

6 Roboter Respot 2, 1 Roboter Taping 21 Roboter Dachstation, div. Stauförderer und Behälter

Produktionsszenario

Dach

MAG

Inline

Respot

Respot

Geo 1 Geo 2

Respot

Layoutvariante:

§ Mix, Integration

§ Brownfield, Hallen Shedbau

§ 16,6 EH / h

Mäander Layout - Two Models

35Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Kommissionierung Spriegel

Kleben Seitenrahmen

Taping

Geo

Aufgabe Boden vst.

Framingstation bis 3 Typen erweiterbar. Zunächst nur Basiseinheit mit kurzer Linearachse, 1 Laufwagen und Zustelleinheit verbaut

Details of the Layout

36Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

2 neue Spannrahmen

1 neue Kleberanlage

1 neue Bauteilablage

5 neue Greifer

2 neue Bauteilbehälter

Framingstation auf 2. Typ erweitert. Verlängerung Linearachse, 1 Laufwagen neu hinzu, 1+1 Spannrahmen hinzu

Details of the Layout with Additional Equipment

37Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Comparison of Space and Investment

Production Space and Investment (direct und normed)

Model A solitary Model A Mäander

Model B solitary Model A and Model B Mäander

4500 m² 100 % Basis Mio. € 4300 m² 102 % Basis Mio. €

4300 m² 41 % Basis Mio. €3100 m² 95% Basis Mio. €

Σ = 7600 m²

38Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.213SW

Volume

Time

Model AModel A + B

Model A + B + C

100

150

50

Units / day

Sce

na

rio

1

Sce

na

rio

2

Sce

na

rio

3

Sce

na

rio

4

0

Assumption:2 shifts/day, each 8 hours

Production Volume Scenarios for 3 Models of different OEMS

39Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Simulation Result

14.234SW

Model A (~60%)

Model B (~30%)

Model C (~10%)

Total performancein average 172 units/day

Share

100

0

[%]

60

40

20

Single valueSliding average

[IPH]

40Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Evaluation of Investments (Price Tree)

14.200SW

S00

S11

S12

Meander

Solitude

Production unit development

Production lines

Model integration

A

B

C

41Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Comparison of Investments of theSolitude and Migration Concept

14.109SW

Solitude concept Meander concept

Investments 13,8

10

5

0

9,3

4,8

[Mio. €]

Mo

del

AM

od

el C

Start scenario

4,22

Sce

na

rio

1

Mo

del

B

5,32

Model A

Sce

na

rio

2

Integration Model B

ProductionSystems

Processtechnology

Robotics

others

Integration Model C

8,12

Sce

na

rio

4

others

ProductionSystemsRobotics

Processtechnology

7,42

Sce

na

rio

3

42Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.114SW

Cash Positive

Cash Negative

Time

Cumulated Cash Flow[Mio. €]

SOP(C)SOP(B)- 4 M

SOP(A)- 6 M

- 10 months

Interesteffect

StartCash FlowModel A

StartCash FlowModel B

Investmentsingle-line Model B

Meanderbase

Expansion of investment forvolume and/or Model B

Base

Interest effect

Cash Flow of a Migration Production StructureCompared to a Solitude Production

43Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.100SW

high

medium

low

low medium high

Case B: For increasing volume under-investedhigh variable unit production cost

Volume

Increasing variable Production unit cost

Inestment

Raising fixedproduction cost

Case A: for decreasing volume over-investedhigh fixed unit production cost

Case A

planned volume

planned volume

Case B

new volumeafter appr. 2 years

new volume

Case BMedium production withlower investment, increasingunits produced

Economic Development in Case of Volume Deviation

Case AHigh volume with high investmentin order to minimize unit cost,decreasing units produced

44Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Economic Development of Production Volume Deviations

high

medium

low medium high Volume

Maximum variableproduction cost

Investment

Case A: avoidance of high fixedproduction cost

Case B: avoidance of high variableproduction cost

Increasing volume; under investedhigh variable production cost

Overinvested for low volume,low profitabilityHigh fixed production cost

Maximal fixedproduction cost

Vehicle B

low

Investment step

High volume with migratinginvestment in order to minimizeunit cost

Investment path

De-investmentpath

Optimal migration path

Vehicle A

45Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Production Strategies

Modulare plant Wildemann 1988

Fractale plant Warnecke 1991

Bionic manufacturing Okino 1993

Holonic manufacturing HMS 1994

Network plant Wiendahl 1996

Migration Manufacturing

Strategy Founder Year

46Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Summary

- Life-style effects in the market and technical innovations require continuously

new car models in short sequence and with decreasing product life-cycle.

­ A high competitive pressure requires low cost and

low budget production concepts.

­ The Body-in-White production is a key element in the automotive

manufacturing process.

­ A Body-in-White production based on the new Migration Concept is much more

advanced compared to the existing production concepts in respect of flexibility, economics and investment and market risks.

­ Migration Manufacturing is a new concept for factory planning. It reflects the idea that plant layouts are a living organism that pro-acts with market and technology changes.

47Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner

Thank you for your attention!

Publisher: PZH Produktions-technisches Zentrum

ISBN-10: 3939026638

ISBN-13: 978-3939026631