FROM THE FIELD
DAIMLER – CONVERSION TO PAPERLESS PRODUCTION
At Daimler AG’s production site in Duesseldorf, the challenge was to convert an assembly line for vans to paper-free production with a flexible, highly available MES (Manufacturing Execution System).
We achieved the following objectives:
- Visualization of information using multi-touch devices attached to the conveyor systems
- Display of information depending on vehicle model and position of the vehicle
- Efficient and intuitive control and monitoring of the production process
- Display of a virtual map of the production line
- Transmission of information and work instructions/procedures to mobile terminals
- Synchronization of information with the quality and production system (MES) in real-time
DAIMLER – IMPLEMENTATION AND DETAILED PLANNING FOR BODY PLATFORM Z1 FOR THREE FACTORIES
The automobile manufacturer Mercedes Benz required planning and realization of a body-in-white production facility for the body platform Z1 for its C-Class in Bremen, Tuscaloosa (USA) and East London (South Africa). Special attention for this turnkey project was put on compliance to milestones to ensure a high level of planning security.
The tasks included:
- Simultaneous engineering planning and drafting of specifications for all locations
- Realization and detailed planning during the 3D engineering phase in all three factories
- Start-up support by planner on site in Bremen and Tuscaloosa
- Joint “cost walk” with the customer to achieve the objectives of the cost specifications
- Use of the special joining processes Robscan, HSN, clinching, FDS and Impact
VOLVO CAR CORPORATION – SUPPLY OF PROTOTYPE WELDING FIXTURES
Volvo Car Corporation and its subsidiary Polestar were required to create underbody welding fixtures for pilot production. This was the first project to be realized in ongoing collaboration with the client. The subsequent small series production on the fixtures takes place in Chengdu, China.
The following scope has been developed:
- Creation of clamping concepts in coordination with the client
- Securing the static accessibility of the joining tools
- Construction of welding devices according to sheet metal conditions and joining specifications
- Component procurement and assembly of welding fixtures
- Calibration of the devices
- Alignment of the fixtures with the customer on site
- Production and delivery of welding spot templates
“We are very satisfied with the devices that EDAG PS has developed, supplied and built for us. First measurements from the assemblies show an incredibly good result.”
VOLVO CAR CORPORATION / POLESTAR
VOLVO CAR CORPORATION – DESIGN AND DELIVERY OF THE BODY IN WHITE FIXTURES FOR THE ADHESIVE JOINING OF CARBON FIBER REINFORCED PLASTIC PARTS
The Body in white (BiW) production planning and manufacturing engineering for adhesive processes of carbon fiber reinforced plastics parts (CFRP) for the Polestar 1. The task was to ensure the feasibility of the BiW assembly process from planning, prototype build phase until including realization of the serial production in Chengdu, China
Main tasks performed:
- Securing “design for manufacture” of the BiW design (reg. adhesive joining)
- Definition of clamping points and locator positions
- Design and delivery of adhesive joining fixtures
- Digital mock-up verification of kinematic features on the fixtures for a defined assembly sequence
- Specification of robotic adhesive application cells
- Digital mock-up verification of accessibility for integration of mechanical fasteners
- Definition and screening of non-destructive testing methods for the CRFP-metal joints
- Process FMEA and quality control concept for BiW area
Further information about this project (german only): AUTOMOBIL PRODUKTION
VOLKSWAGEN GROUP – BODY-IN-WHITE DEVELOPMENT FOR EIGHT FACTORIES IN SIX COUNTRIES
For the Volkswagen group (VW, Audi, Seat and Škoda), EDAG PS assumed responsibility for the complete body-in-white development of the PQ-35 platform – from product development up to the final line. The PQ-35 platform is used in ten different vehicle models, produced in eight factories and six countries.
The special feature of this complex project was not only the manufacturing plan, but also the development of the product with the partner.
The sub-projects involved were:
- Product development of the entire substructure of the PR-35 platform
- Production of 2000 prototypes of the substructure
- Simultaneous engineering and concept planning for all factories
- Drafting of specifications for all PQ-35 body-in-white production lines
- Realization of parts of the body-in-white production lines
VOLKSWAGEN – 3D-SYSTEM SCAN FOR THE OPTIMIZATION OF PRODUCTION
An existing production line in Emden was to be converted for the production of a new model. The existing plant was scanned to get an overview of the current, actual structural conditions.
The existing plant data could then be checked and adjusted based on the scan results.
- Checking the pitch points of the facility
- Distance measurements
- Integration of digitized objects in the design/simulation
The project management of the integration could be implemented faster and at a higher quality due to the improved information situation.
HAEMA – FACTORY PLANNING OF A PRODUCTION CENTER FOR BLOOD PRODUCTS
A production center for blood products had to be planned in Leipzig for the nationwide blood-donation service Haema. A special challenge here was to comply with the specifications on the temperature ranges to be maintained when processing the blood products.
The project milestones were:
- Rough and detailed planning of the production center for blood products
- Modification of the automation level with regard to efficiency, ergonomics and quality
- Simulation-based validation of all work processes
- Energy-efficient design of lines and building technology
“We are very satisfied with the new production plant for our blood products. It is extremely energy efficient, largely automated and as smooth in operations as was shown during the simulation in the planning phase.”
KYOCERA DISPLAY – LOGISTICS CONCEPT FOR CHINA, EUROPE AND THE USA
Kyocera Display Europe GmbH supplies automotive manufacturers worldwide with displays for inclusion in their car production processes. In cooperation with Kyocera Display, EDAG PS has developed a new logistics concept for China, Europe and the USA, including the definition of the material flow and the costs for handling and support.
The following objectives have been achieved:
- Identification of all relevant logistics data
- Definition of the internal material- and information flows in the individual goods distribution centers
- Specification of the transport and logistics costs over the life cycle of a vehicle – including the processes and costs for reusable handling in Germany
SMA SOLAR – POTENTIAL ANALYSIS OF A STATION STOP
SMA Solar Technology AG is a company specialized in the production of photovoltaic systems technology. The increasing cost pressure and higher expectations of customers on the functionality of a photovoltaic power station, which is the technical center of a large plant, were the starting point for the project.
By redesigning the overall structure, we were able to reduce costs by a total of 24%, representing a sum total of 4.5 million Euros. We achieved this by:
- Analysis of the cost drivers in the overall concept
- Proposals for improving the overall structure, the base frame design, control cabinet arrangement, cable routing, processes, assembly and logistics processes
- Conceptual development of alternative concepts
- Demonstration of cost savings
CARLSBERG GROUP – DEVELOPMENT OF A SECURITY CONCEPT INCLUDING RISK ASSESSMENT
Carlsberg in Denmark required the drafting of a risk assessment and a safety concept for a production line. Naturally, this had to be aligned to the legal framework conditions in Denmark.
The project comprised the following points:
- Development of a risk assessment
- Drafting of a safety concept
- Drawing up a safety layout for production
- Checking the wiring diagrams
- Safety-related project support
- Coordination with the Danish authorities
- Intensive on-site consulting
TROX TLT – OPTIMIZATION OF IMPELLER PRODUCTION
At TROX TLT GmbH in Bad Hersfeld, one of the world’s leading suppliers of high-quality fans, the project was to optimize the existing process of the impeller production:
- Development of an optimized production process
– Material flow
- Tendering and procurement monitoring of manufacturing facilities and resources
- Installation and commissioning of the production at EDAG
- Production of the first parts at EDAG
- Support during commissioning and SOP
The result was a considerably reduced cycle time (75% shorter) and use of less personnel.
“As a mid-sized manufacturing company, our product is the actual core competence. However, to be able to manufacture this at a high degree of automation and using the latest production techniques, we needed a lot of different specialists. We can’t afford this and are therefore happy to have found all of this at EDAG PS. My manufacturing engineers are therefore always up to date and have found the right sparring partner in EDAG PS, no matter what technology is required. An example from our company is the optimization of axial impeller production. Our turnaround times have been drastically reduced, while at the same time reducing error rates!”
ARCELORMITTAL – GENERAL PLANNING OF THE MEDIA SUPPLY
EDAG PS assumed responsibility of general planning for the media supply in a rod rolling mill in Duisburg for the global steel company ArcelorMittal. As the appointed general planner, we controlled and ran the installation-, design- and approval planning, the site management, and the commissioning of the project.
The scope of delivery and performance consisted of:
- Installation planning
- Design and approval planning
- Support structure planning
- Civil engineering and building construction
- Detailed planning (implementation planning)
- Steel construction planning
- Process-oriented plant engineering
- Piping design
- Construction supervision
- Site management