CASE | Manufaturing 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

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