Digital Manufacturing Engineering – CREATIVE

Virtual Commissioning For Automotive Body Assembly

creative — Wed, 26 May 2021 07:37:39 +0000

Learn How CREATIVE Executed Virtual Commissioning for Automotive Body Assembly Line

Client:

Global Automotive OEM

Industry:

Automotive

Services:

Virtual Commissioning, Digital Engineering, Plant Simulation, System Layout, Robotic Simulation, Ergonomics Simulation.

Project Background

Virtual Commissioning for Automotive Body Assembly Line Consisting of Robotic and Manual Stations.

Our Scope

Robotic Simulation: Process validation, tool validation, cycle time prove out, risk and safety assessment. Robot extraction plans. Design of complete work cells with comprehensive models. Offline programming to validate collision free robot motion and cycle times
Ergonomics Simulation: Simulation of human factors including injury risk, user comfort and fatigue. Compliance with health and safety standards, process feasibility and elimination of human performance issues
Plant Simulation: Discrete event simulation, optimization of material handling and equipment utilization. Comprehensive throughput analysis, bottleneck detection and countermeasures. Integrated energy optimization
Virtual Commissioning: Debugging automation control logic and PLC code in virtual environment to ensure automation equipment will perform as designed thereby eliminating installation time delays and cost. Simulation of production lines to identify and correct errors related to design and functions. Thoroughly test and evaluate interplay of electrical, mechanical and control automation

What we did

We deployed our automotive assembly automation domain experts to serve as program managers for this project. Our team displayed flawless knowledge and a rich experience of automotive virtual commissioning, mastery of OEM standards and processes and substantial manufacturing knowledge. We were able to identify critical issues through our robotic, ergonomics and plant simulations which saved our customer five weeks of time and substantial costs. The quality, timeliness and responsiveness of our team was greatly appreciated by our customer.

Engineering cost savings

35%

Project cost savings

1.5M

Few words from our client

CREATIVE truly worked as an extended part of our engineering team to meet critical delivery schedules and technical challenges. Their expertise in virtual commissioning saved us a lot of time and money by identifying issues early in the game. They have been very instrumental in our success in large digital engineering projects. They thrive on constructive feedback from our team and make themselves available 24x7 and also during holidays. We are delighted to have CREATIVE in our corner.Vice PresidentVirtual Automation and Assembly

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Digital Engineering for Automotive MIG Welding

creative — Wed, 26 May 2021 07:31:48 +0000

Learn How CREATIVE Delivered Digital Engineering For Automotive MIG Welding

Client:

Automotive Tier-1 Supplier

Industry:

Automotive

Services:

Digital Engineering for MIG Welding Application Including Process Planning, System Layout, Concept Designs for Fixtures and Equipment, Robotic Simulation, Manufacturing Drawings, Offline Programming, On Location Support

Project Background

Production of automotive chassis and frame structures encompasses a substantial amount of MIG welding due to stringent strength, accuracy and load carrying requirements

Our Scope

Process: Defining Product Structures, Weld Distributions, Weld Torch Selections, Cycle Time Study and Line Balancing
Layout: Generating Cell Layouts With Equipment Positions and Defining the Media Requirements in the Plant, Ensuring the Safety of the Lines
Concept Design: Design of Geometry Fixtures for MIG Welding, Rotary Trunnion, Modular Grippers
Robotic Simulation: Process Validations, Tool Validations, Cycle Time Prove Out, Risk and Safety Assessment. Robot Extraction Plans
Manufacturing Drawings: Preparation of 2D Manufacturing Drawings with Bill Of Materials
Offline Programming: Downloading Offline Programming using Robotic Controllers, Validating Programs on the Floor
On-Location Support: Manufacturing and Prove Out with Cycle Time Optimization

What we did

Our program managers for this project were world class MIG welding domain experts with hands-on experience with over 10 global automotive OEMs. We executed this project round-the-clock for 14 weeks to complete high quality deliverables under very stringent time and quality requirements. We made high value add recommendations to our customer at each stage of the project from process planning, system layout, concept design all the way to robotic simulation, manufacturing drawings and offline programming. We deployed our proprietary in house software packages to save the customer lot of time and money in addition to providing high quality deliverables.

Proprietary software

30%

Faster delivery

25%

Few words from our client

Our team has been very impressed with CREATIVE'S experience and their understanding of project requirements and the commitment of their engineers. They supported us 7X24 for 3 months at a stretch to deliver major milestones ahead of time. We are very fortunate to have CREATIVE as a valued long-term partner.Vice PresidentDigital Strategy

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Digital Automotive Body Robotic Assembly Automation

creative — Wed, 26 May 2021 07:20:13 +0000

Learn How CREATIVE Delivered Digital Engineering for Automotive Body Robotic Assembly Automation

Client:

Global Automotive OEM

Industry:

Automotive

Services:

Digital Engineering Including BIW Line Process Planning, System Layout, Concept Designs for Fixtures and Equipment, Robotic Simulation, Manufacturing Drawings, Offline Programming

Project Background

Integration of 2 new Body Side Outer Variants of an SUV for an existing line with 2 other products in China. The engineering was undertaken in India and Installation and commissioning executed in the China facility.

Our Scope

Process: Integration Study of the Products, Defining New Product Structures, Weld Distributions, Weld Gun Selections, Cycle Time Study and Line Balancing
Layout: Legacy Layout Update with Changes in Equipment Positions and Definition of Air, Water and Electricity Requirements in the Plant to Define Piping Space, Cable Trays Required to Ensure Safety
Concept Design: Design of Geometry Fixtures for Spot Welding, Rotary Trunnion, MIG Welding Fixtures, Modular Grippers, Sealer and Welding Equipment
Robotic Simulation: Process Validation, Tool Validation, Cycle Time Prove Out, Risk and Safety Assessment. Robot Extraction Plans
Manufacturing Drawings: Preparation of 2D Manufacturing Drawings with Bill of Materials. Preparation of Sequence Sheets and Pneumatic Plans
Offline Programming: Offline Programming and Download Using Robotic Controllers, Validate Programs on Shop Floor
Onsite Support: Installation and Prove Out with Cycle Time Optimization in China

What we did

We deployed our automotive assembly automation domain experts to serve as program managers for this project. In addition to executing this multifaceted engineering project in a record time, we provided our customer with several recommendations to improve performance, streamline the layout and cut down costs through standardization, modularity and tool reuse because of our indepth experience with the customer’s product line.

Engineering cost savings

35%

Faster delivery

25%

Few words from our client

CREATIVE has been very instrumental in our success by deploying a team of 50 engineers in supporting our large Digital Engineering projects for automotive body robotic assembly automation. Their dynamic resource management coupled with their highly talented multidisciplinary team rivals anything that I can find locally in the US. They work as an extension of our engineering team and they have excellent domain knowledge in body shop line engineering. We are looking forward to a long term expanded relationship with them.Vice PresidentVirtual Automation and Assembly

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Harness our deep domain expertise with NextGen technologies
to lead in Digital Innovation

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