Digital Factory and Virtual Manufacturing at Volvo Cars

Dr.
$Dan$Lämkull$
Volvo$Cars$Group$ digital factory
digital andand
factory Virtual
manufacturing at volvo cars
Virtual
Manufacturing$Engineering$
Virtual$Methods$&$IT$
$
$
How Simulation Is Used ToatVerify
manufacturing volvoFlawless
Production Of Future Car Models
Far Before Thecars
Start Of Production
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, Dr Dan Lämkull, Volvo Cars Group Date Created: November 14, 2016 1
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

Background virtual manufacturing at
volvo cars – history - today
1984 1988 1990 1993 1997 1999 2006 2010

2010 2013 2016
2016
Start with Advanced OLP OLP Teamcenter Assembly One Engineering
CATIA Engineering Painting BiW Tecnomatix instructionsEnvironment
Robotics Production 100% Spotweld FA is Catia V5 in Teamcenter -
Evaluation: 100% involved in OEE
Scanning of
Scanning of
ROBCAD selected Virtual Mfg all plants
all plants
Toolset - Manufacturing
Engineering* Within the Manufacturing
Facility, Engineering organization
Tooling
and there are Virtual
Equipment
>800
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.
*) Manufacturing Engineering approx. 1 000 people
Ips application setup @ volvo
cars
Flexible Structure Simulation
approx. 250 uesrs
Assembly Path Planner Inspection Path Planner
40 150 30
Virtual Paint,
Robot Path Planner Gluing, Sealing Virtual Luggage Packer IMMA
6
3
10 6
ips – industrial path solution
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
IPS- Robotics
-  Sealing
-  Robot Balancing
-  Robot Cable
-  Painting/Gluing
Continously developed
and further improved in
IPS- Rigid Body
functionality in several
first tested@VCC. Continously IPS- Flexible IPS- 3.2
developed and further improved research projects.
is used for In November IPS 3.2
in functionality simulation of will be implemented.
IPS- Rigid Body flexible materials Including Point
is selected as Cloud, Wiring
simulation tool for Harness Editor,
assembly analyses IPS-TC integration
and IMMA.....
2002 2005 2006-2011 2009-2012 2011-2016 2016

Research projects Research project
Changing conditions and future
challanges
From To
2012 2016 2020

•  Engineering only in Sweden •  Global Engineering •  3x Engineering Output
•  2 flex. assembly plants (EU, China, Suppliers) •  50% lead time reduction
•  1 engine plant •  30% lead time reduction •  > 4 flex. assembly plants
•  1 stamping plant •  Limited physical builds •  > 2 engine plants
•  Volume ~400k vehicles/year •  4 flex. assembly plants •  > 3 stamping plants
•  2 engine plants •  Volume ≥ 800k vehicles/year
•  3 stamping plants
•  ~ 600k vehicles/year
scalable platform
But
architecture More
models!
Rapid
shorter follower!
how? When your are small…

ttm/lead
time
first within safety,
environment and
design around you
Sales
volume AUDI operating profit 2012 : ∼ 5 B£
spa
[k]
1800
27
1600 scalable platform
1400 architechture
1200 14
1000
11
800 10
600 8
400
200
X: number of products
0
1990 1995 2000 2005 2010 2015 [year]
shorter ttm/lead time
Leadtime from PS to J1: 20 months
New XC90 – 36 months
New S80 – 40 months
Volvo S80 – 50 months
Volvo 850 – 60 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:
•  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 Process/Operations" Tooling"
Line design"
All products in sequence" Layout! Flowsimulation!
Balancing"
Requirement Verification" Line/Station context!
Mfg features"
Logistics"
Annual & Pre-PS PS to J#1
Optimal standard On-the-shelf

process solutions Plant & Program specific
Vision
Vision Standard
Standard Plant/Program
Plant/ProgramSpecific
SpecificBOP
BOP
BOP
BOP BOP
BOP
Production Issue Line/Stn KPI’s - Scanning

Manufacturing Plant
Requirements (ME) Solutions
Manufacturing BOP
Strategy Requirements
Manufacturing Design BOM / BOP
Requirements
Specifications (PD) compatability
driven by BOP
Plant Current status in

PlantXX
"
Plant X at a given
BOP
BOP date in time
Feedback
Offline changeover
Geometry"
Operator training! PLC" Robot" Ergonomics! TF1 + TF2"

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
Layout - what do we have today?
  We have 2D layout, equipment models, and very good status
on robot cells
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
plant scanning and layout
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
plant scanning and layout - Previous
attempts attempts to make CAD
Numerous
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 hybrid model - use cases
Virtual Linewalks
Operation
Virtual Arena Area in the plant discussed

during Virtual Build Event
Date Created: November 14,
Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group 19
2016
Virtual Linewalks
Body window studies
Virtual Linewalks
Body window studies
2D layout validation
Virtual Linewalks
Body window studies
2D layout validation
Installation verifications
Scanned Virtual model

Virtual Linewalks
Body window studies
2d layout validation
Plant visualization
Virtual Linewalks
Body window studies
2d layout validation
Plant visualization
Visualize rebuilds
what do we miss in our simulations
today?
- The Plant
Material Façade
Line, working height
Distance between cars on line
- The holistic view
- Product and product

close equipments are
Digital Factory and Virtual Manufacturing at Volvo Cars, Dr Dan Lämkull, Volvo Cars Group
included Date Created: November 14, 2016 25
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!
verify assembly case and
logistics/layout
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)
Virtual verification of manual
assembly tasks
Virtual verification - hand access
studies
Virtual verification - tool access
studies
Virtual verification - field of views
Virtual verification - working postures
Examples of posture studies

and suggestions for improvements
further research/development of the
imma manikin
  More realistic look
  Collaboration with robots
  Realistic walk
  Company specific evaluation tools
more realistic look
Collaboration with robots
Realistic walk
Company specific evaluation
tools
Work condition
Verification in virtual
environment using ips
Simulating flexible materials in engine bay

Simulating Suspension Kinematics

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.
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.
Virtual Process Training Help Buttons
Show&where&part&&
shoud&be&assembled&
Show&&
•  If an operator makes a mistake in opera-on&
text&
PCPT immediate feedback from the
software will be provided. The operator Select&tool& Select&part& Reset&view&
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
Diﬃculty&Level&1&&
4)  Click&on&highlighted&part&
Feedback&on&the&
performed&training&
1)  Read&opera-on&text&
5)  Step&1;4&is&repeated&for&each&
process&un-l&end&of&sequence&
2)  Observe&which&
tool&to&use&
3)  Observe&part&number&and&
descrip-on&(right&mouse&buJon)&
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
example of virtual
manufacturing within biw
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...
Thank you for your attention!
Questions?

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Dr.

 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

1984 1988 1990 1993 1997 1999 2006 2010

2002 2005 2006-2011 2009-2012 2011-2016 2016

2012 2016 2020

how? When your are small…

New XC90 – 36 months

New S80 – 40 months

Volvo S80 – 50 months

Volvo 850 – 60 months

We have to deal with all different simulation methods/areas related to

All products in sequence" Layout! Flowsimulation!

Optimal standard On-the-shelf

Production Issue Line/Stn KPI’s - Scanning

Plant Current status in

Operator training! PLC" Robot" Ergonomics! TF1 + TF2"

 We have problems managing plant layouts over time

 Being a small manufacturer, the plant becomes complex

 We need layout in 3D and layout information easily

 It should be possible for any manufacturing engineer to

 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

Each point has information of

The point cloud can easily be clustered as a

Our experience: Not working;

Virtual Arena Area in the plant discussed

Scanned Virtual model

- The holistic view

- Product and product

Use Point Cloud As Is!

 Most manikin software are closed and hard to integrate

 Volvo Cars is therefore developing an own manikin in a research project

Examples of posture studies

 Collaboration with robots

 Company specific evaluation tools

Simulating flexible materials in engine bay

Simulating Suspension Kinematics

• In PCPT the operator can train on different

• PCPT also enables the operator to train on different variants,

• Any mistakes made are

• To be approved on a level, the operator must

Especially we are training:

- More than 4000 employees have been trained during 2005-2014

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  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

  We have problems managing plant layouts over time

  Being a small manufacturer, the plant becomes complex

  We need layout in 3D and layout information easily

  It should be possible for any manufacturing engineer to

  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

- Product and product

  Most manikin software are closed and hard to integrate

  Volvo Cars is therefore developing an own manikin in a research project

  Collaboration with robots

  Company specific evaluation tools

•  In PCPT the operator can train on different

•  PCPT also enables the operator to train on different variants,

•  Any mistakes made are

•  To be approved on a level, the operator must

-  More than 4000 employees have been trained during 2005-2014