Status report on Virtual Manufacturing at Volvo Cars

Transcription

1 Status report on Virtual Manufacturing at Volvo Cars Anders Carlsson Manufacturing Engineering Volvo Cars Sida 1

2 Business challenges Product lifecycle PV Amazon P / / /SV70 C70 SV40 S80 V70 V70XC S60 XC90 S40 V50 C70 C30 S80 V70 XC70 Sida 2

3 Business challenges Product lifecycle Development time 850 Year Development Tool Development & Manufacturing Pre Series S80, V70 Dev. Tool Dev. & Man. Pre Series S60 Dev. Tool Dev. & Man. Pre Series XC90, S40 V50, S80' Dev. Tool Dev. & Man. Pre Series. Dev. Tool Dev. & Man. Pre Series Sida 3

4 Business challenges Product lifecycle Development time Fewer plants, higher volume Sida 4

5 Business challenges Product lifecycle Development lead time Fewer plants, higher volume, offline change over Global development Sida 5

6 Business challenges Product lifecycle Development lead time Fewer plants, higher volume, offline change over Global development More cars Variants & changes Resources Lead Time In shorter time With fewer plants With global usage Sida 6

7 Development = Virtual development Sida 7

8 Body shop Sida 8

9 Paint shop Sida 9

10 Assembly Sida 10

11 Ergonomics Sida 11

12 All Manufacturing disciplines go virtual! Sida 12

13 Four aspects of Virtual Development Sida 13

14 Information concept from 1999 Product structure Process structure Hierarchy Plant & Resource structure Sequence S80 Sida 14

15 Single master model Manufacturing After sales CUSTOMERS Purchasing CAE SINGLE MASTER BOM + CAD Etc. etc. BOM management Vehicle Steering system Design in context Virtual = / Physical Part usage - Steering wheel Position - LHD position Edit part content CAD - Steering wheel CREATORS Engineer Edit CAD content Alignment level = End item level Sida 15

16 Managing the manufacturing complexity Standard Product BOM Standard BOP Specific Product BOM Plant 1 View BOP for A Specific BOP for Product A Plant 2 View BOP for A Specific BOP for Product B Plant 2 View BOP for B Plant constraints Product constraints BOP = Bill of Process Plant 1 Structure Plant 2 Structure Sida 16

17 Toolset Family for Manufacturing CATIA V5 TCVis & IPS Tecnomatix Teamcenter Product Structure for CAD Process planning define process steps define sequence Plant structure Layout Equipment management Sida 17

18 Sida 18

19 Training for Manufacturing Engineering Process Simulate Robotics and Ergonomics Simulation Simulation Engineers 3 days IPS Automatic path planning tool Manufacturing Engineers, FA 1 day TCVis Advanced studies 2 days 103 Process Designer C3PNG for Painted Body 3 days Teamcenter Manufacturing C3PNG for Final Assembly, Tooling, MP&L, QA 4 days ebop Data model Part & Weldpoint Process review distribution Report creation/export Resource search 3D rough layout Building a process Process Templates Configure variants Incremental change Classification and Resource Management Teamcenter Basics All staff participating in program work at Mfg Eng. Requirement for access to Teamcenter. 2-3 days Intro to C3PNG Product Structure Version handling PLM, database driven dev Manufacturing Structure Effectivity Teamcenter overview Factory Structure VisMockup (Number of trained users) Sida 19

20 Toolset Family for Manufacturing CATIA V5 TCVis & IPS Tecnomatix Teamcenter Product Structure for CAD Process planning define process steps define sequence Plant structure Layout Equipment management Sida 20

21 Next step Automation & Business Confidence Ergonomics (within MERA) Issue date: , Copyright 2008 Volvo Cars, All rights reserved Page 21

22 Simulation and Path Planning of Flexible Materials (within MERA) Interior Interi material ö r material Real world Virtual world Hoses Door Dsealing ö rrt ä tningar Wire net Bending of a hose The load distribution in bent hoses Green; bending in reality Blue; Simulated bending Violet; Designed, thought bending Issue date: , Copyright 2008 Volvo Cars, All rights reserved Page 22

23 Virtual Paint (within MERA) Issue date: , Copyright 2008 Volvo Cars, All rights reserved Page 23

24 Thank You Sida 24