CASE | Vehicle Engineering
Robotic Simulations for Electric Vehicle Chassis
The client was looking for a partner with experience with In-Process planning, Robot Process simulation and Off-Line Programs for all BIW segments for major automotive OEMs.
THE CHALLENGE
- Handling multiple BIW production lines, each with diverse process standards, for different OEM vehicle programs and mixed metal body structures
- Consolidating the BIW platform utilizing flexible manufacturing and modular body design
- Reusing assets of existing facility for new product introduction (NPI) while providing harmonization
- Creating a visible and transparent production system while balancing volume flexibility and rigidity
- Debugging shop floor to develop standard operating procedures (SOP) and product sustainability
- Project scope varying from green field (setting up new production lines) to brown field (integrating new models on existing production lines)
- Meeting the client’s expectations considering they had never outsourced a program to this degree.
THE COMPANY
One of the world’s leading suppliers of intelligent, robot-based automation solutions for international customers including leading automotive OEMs and general industry manufacturers.
THE SOLUTION
- Conducting a manufacturing assessment, including process planning and detail process engineering, and adopting a logical approach
- Developing a flexible assembly line, including complex tools and manual and robotic parts, to accommodate multiple high-end models
- Designing BIW robotic assembly line including various joining processes (i.e., spot welding, selfpiercing rivets, gluing, clinching, hemming, etc.)
- Focusing on resource utilization, and using cutting-edge simulation tools, to validate all processes
- Utilizing experience and expertise, and incorporating OEM standards, while determining whether to handle as a green field or brown field project
- Owning all technical aspects from process planning to product launch while meeting OEM constraints
Optimized process solutions led to cost savings
Reduced installation and commissioning time, decreased time to market
Process optimization and quality management
Flexibility, standardization, and reutilization of production setup
