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Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 1
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digital factory and Virtual manufacturing at volvo cars
How Simulation Is Used To Verify Flawless Production Of Future Car Models
Far Before The Start Of Production
digital factory and Virtual
manufacturing at volvo cars
How Simulation Is Used To Verify Flawless
Production Of Future Car Models
Far Before The Start Of Production
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 Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 2
Background virtual manufacturing at volvo cars – history - today
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 3
One Engineering Environment
- OEE
Scanning of all plants
2010 2016 1984 Start with
CATIA Robotics
1988 Advanced
Engineering Production
1990
Evaluation: ROBCAD selected
1993 OLP
Painting 100%
1997 OLP BiW
Spotweld 100%
1999
FA is involved in Virtual Mfg
2006 Teamcenter Tecnomatix
Catia V5
Scanning of all plants
2010 2013 Assembly
instructions in Teamcenter
2016
Toolset - Manufacturing Engineering*
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 4
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.
>800
Facility, Tooling and Equipment
*) Manufacturing Engineering approx. 1 000 people
Ips application setup @ volvo cars approx. 250 uesrs
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 5
Flexible Structure Simulation Assembly Path Planner Inspection Path Planner
Robot Path Planner Virtual Paint,
Gluing, Sealing IMMA
40 150 30
10 6
Virtual Luggage Packer
3
6
ips – industrial path solution
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 6
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.
Background: IPS from research to implementation
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 7
2002 2005 2006-2011 2009-2012
IPS- Rigid Body first tested@VCC. Continously developed and further improved in functionality
IPS- Rigid Body is selected as
simulation tool for assembly analyses
2011-2016
IPS- Flexible is used for
simulation of flexible materials
Research project 2016
IPS- 3.2 In November IPS 3.2 will be implemented. Including Point Cloud, Wiring Harness Editor, IPS-TC integration and IMMA.....
Research projects
IPS- Robotics - Sealing - Robot Balancing - Robot Cable - Painting/Gluing Continously developed and further improved in functionality in several research projects.
Changing conditions and future challanges
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 8
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
2020 • 3x Engineering Output • 50% lead time reduction • > 4 flex. assembly plants • > 2 engine plants • > 3 stamping plants • Volume ≥ 800k vehicles/year
More models!
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 9
Rapid follower! shorter
ttm/lead time
But how?
When your are small…
scalable platform architecture
first within safety, environment and
design around you
first within safety, environment and
design around you
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 10
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1990 1995 2000 2005 2010 2015
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AUDI operating profit 2012 : ∼ 5 B£ Sales
volume [k]
X: number of products
spa scalable platform
architechture
[year]
shorter ttm/lead time
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 11
Volvo 850 – 60 months
Volvo S80 – 50 months
New S80 – 40 months
Leadtime from PS to J1: 20 months
New XC90 – 36 months
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:
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 12
• 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 • ... ... ...
layout, scanning, manual assembly & operator training
Tooling"Process/Operations"
Requirement Verification"
All products in sequence"
Offline changeover
Line/Station context!
Production Issue "
Plant X BOP
Plant X BOP
Annual & Pre-PS PS to J#1
Current status in Plant X at a given date in time
StandardBOP
StandardBOP
On-the-shelfsolutions
Requirementsdriven by BOP
BOP Requirements
Plant/Program Specific BOPPlant/Program Specific BOP
Plant & Program specific
ManufacturingRequirements (ME)
Manufacturing Design Specifications (PD)
PlantSolutions
BOM / BOPcompatability
Optimal standardprocess
Vision BOP
Vision BOP
ManufacturingStrategy
Feedback
Logistics"
Balancing"
Line design"
Layout!
Line/Stn KPI’s - Scanning
Geometry"
Mfg features"
Flowsimulation!
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 13
Ergonomics!TF1 + TF2"Operator training! PLC" Robot"
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
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 14
Layout - what do we have today? We have 2D layout, equipment models, and very good status on robot cells
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 15
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
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 16
plant scanning and layout
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 17
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
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 18
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?
plant scanning and layout - Previous attempts
Plant hybrid model - use cases Virtual Linewalks
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 19 19
Virtual Arena Area in the plant discussed during Virtual Build Event
Operation
Plant hybrid model - use cases Virtual Linewalks Body window studies
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 20 20
Plant hybrid model - use cases Virtual Linewalks Body window studies 2D layout validation
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 21 21
Plant hybrid model - use cases Virtual Linewalks Body window studies 2D layout validation Installation verifications
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 22 22
Scanned Virtual model
Plant hybrid model - use cases Virtual Linewalks Body window studies 2d layout validation Installation verifications Plant visualization
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 23 23
Plant hybrid model - use cases Virtual Linewalks Body window studies 2d layout validation Installation verifications Plant visualization Visualize rebuilds
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 24 24
what do we miss in our simulations today?
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 25
- The Plant Material Façade Line, working height Distance between cars on line
- The holistic view - Product and product close equipments are included
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 26
What if…
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!
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 27
verify assembly case and logistics/layout
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 28
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)
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 29
Virtual verification of manual assembly tasks
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 30
Virtual verification - hand access studies
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 31
Virtual verification - tool access studies
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 32
Virtual verification - field of views
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 33
Virtual verification - working postures
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 34
Examples of posture studies and suggestions for improvements
further research/development of the imma manikin
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 35
More realistic look
Collaboration with robots
Realistic walk
Company specific evaluation tools
more realistic look
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 36
Collaboration with robots
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 37
Realistic walk
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 38
Company specific evaluation tools
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 39
Work condition
Verification in virtual environment using ips
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 40
Simulating flexible materials in engine bay
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 41
Verification in virtual environment using ips
Simulating Suspension Kinematics
Verification in virtual environment using ips
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 42
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. Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 43 43
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.
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 44 44
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
• 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
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 45
Help Buttons
Select&part&Select&tool&
Show&&opera-on&text&
Reset&view&
Show&where&part&&shoud&be&assembled&
45
1) Read&opera-on&text&
5) Step&1;4&is&repeated&for&each&process&un-l&end&of&sequence&
Feedback&on&the&performed&training&
Difficulty&Level&1&&
4) Click&on&highlighted&part&
3) Observe&part&number&and&descrip-on&(right&mouse&buJon)&
2) Observe&which&tool&to&use&
46 Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 46
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 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 2005-2014
volvo xc90 – operator training example
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 48
example of virtual manufacturing within biw
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 49
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 50
We would like the Final Assembly area to reach the same maturity level as BiW when it comes to Virtual Manufacturing
A jump toward the future...
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 51
Thank you for your attention!
Date Created: November 14, 2016 Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 52
Thank you for your attention!
Questions?