Virtual Manufacturing Engineering at Volvo Cars

Anders Carlsson

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 1

Business challenges
Product lifecycle
PV Amazon P1800 140/200 300 400 700/900 850/SV70 C70 SV40 S80 V70 V70XC S60 XC90 S40 V50 C70 C30 S80 V70 XC70
Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 2

Business challenges
Product lifecycle Development time
850

Year
1 2 3 4 5

Development

Tool Development & Manufacturing

Pre Series

Dev.

S80, V70

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

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 3

Business challenges
Product lifecycle Development time Fewer plants, higher volume

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 4

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

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 5

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

More cars In shorter time With fewer plants With global usage

Variants & changes Resources Lead Time

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 6

Stra tegic Plan ni

ng

Virtual production development

Virtu al C o mpa tibili t y Phys i

cal C omp atib

Concept Clamping

ility

Rough design

Detailed design

Complete station
Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 7

Stra tegic Plan ni

ng

Virtual production development

Virtu al C o mpa tibili t y Phys i

cal C omp atib

Concept Clamping

ility

Rough design

Detailed design

Complete station
Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 8

Body Assembly

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 9

Paint

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 10

Final Assembly

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 11

A long journey!

1984 Start with CATIA ROBOTICS

1988

1990

1993 OLP Painting

1997

1999

2006

AE Production Evaluation: ROBCAD selected

Body in VMC Teamcenter White Catia V5, ~100% spotweld Tecnomatix

Virtual Manufacturing @ Volvo Cars Utfrdardatum: 21/09/2009 Sida 12

Information concept from 1999

Product structure Process structure Hierarchy Plant & Resource structure

Sequence

S80
Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 13

Toolset Family, Manufacturing Engineering

CATIA V5
Templates enables faster engineering

TCVis / IPS PathPlanner

PC instead of UNIX eM-Planner

Tecnomatix

eM-Engineer Process Designer Process Simulate

Associative design product & tool

Integrated Planning & Simulation application for BiW

Teamcenter

Tight integration to PD

Plant & Resource integrated in Process Planning & Simulation

PD full visibility into the Process

Product structure for CAD Process steps Process sequence

Instant updates from PD

Equipment

JT instead of CATIA (CAD independent)

Virtual Manufacturing @ Volvo Cars Issue date: 21/09/2009 Page 14

Training for Manufacturing Engineering

107 Process Simulate
Robotics and Ergonomics Simulation Simulation Engineers 3 days

55

IPS Pathplanner
Automatic path planning tool Manufacturing Engineers, FA 1 day

TCVis
Advanced studies 2 days

89

Process Designer 120

C3PNG for Painted Body 3 days eBOP Data model Weldpoint Process review Report creation/export search 3D rough layout Part & distribution Resource

Teamcenter Manufacturing
C3PNG for Final Assembly, Tooling, MP&L, QA 4 days Building a process Configure variants Classification and Resource Management Process Templates Incremental change

125

Teamcenter Basics
Product Structure Manufacturing Structure Factory Structure Version handling Effectivity VisMockup

All staff participating in program work at Mfg Eng. Requirement for access to Teamcenter. 2-3 days Intro to C3PNG PLM, database driven dev Teamcenter overview

650
Virtual Manufacturing @ Volvo Cars Issue date: 9/21/2009 Page 15

Toolset Family, Manufacturing Engineering

CATIA V5 TCVis / IPS PathPlanner Tecnomatix
eM-Planner eM-Engineer Process Designer Process Simulate

250 trained users

100 trained users

175 trained users

Teamcenter

Product structure for CAD

Process steps Process sequence

Equipment

650 trained users

Virtual Manufacturing @ Volvo Cars Issue date: 9/21/2009 Page 16

125 trained users

150 trained users