Post on 01-Jan-2016
1
Ready4realityVirtual commissioning
at vcc
Andreas Jonsson MSc.Method Lead BIW
Manufacturing EngineeringVolvo Car Group
Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
2Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
CHINACar & Engine ProductionProduct Development
BELGIUMGentCar production
USACamarilloDesign centre
SWEDENGothenburgHead officeProduct development,Car production
Skövde, Floby and OlofströmComponent manufacturing
MALAYSIAKuala LumpurAssembly factory
SPAINBarcelonaDesign centre
DENMARKCopenhagenRD Centre
Volvo Car Group$9B
USACharlestonManufacturing Plant
3Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Our journey forward
4Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Moremodels!
Rapidfollower!Designed
around you Truly
global
5Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Moremodels!
Rapidfollower!
But how?
When your are small…
Designed around
you Truly global
6Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
>80M
0,5M
7Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
ShortenLeadtime
(40 to 30 Mts)
FlexiblePlants
Decisions solely on Virtual Data
Fast and nimble
Reduce physical
prototypes
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Virtual trust enable more, earlier descisions with high quality
Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
High detailed models
High Quality PLM data
Complete simulation models(Incl. Signals & behaviour models for all equipment etc.)
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Current capabilities
Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
30+ engineers within process simulationExtensive standards & specifications (Sim, Robot, Plc)VOLP – Volvo OffLine Programming tool
Not utilizing the full potential…
10Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Ready 4 reality achieve higher maturity level much earlier
Use what we already
have
Add the real control system and
Code
Virtual Commissioning captures the whole station logic!
fully verified process without
physical installation
11Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
PS PC FDJ TT J1
Core phase
Virtual commissioning
Develop Process/product PLC, installation and
commissioningInstallation and commissioning
Develop Process/product and
PLC
development logic much higher virtual focus
Invest more time here… … to gain time here
Complete virtual installationDevelop More robust processesVerification without physical prototypesDebug process logic off-line
12Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Implementation step by step
2013 2014 2015
Decision to include VC in car projects
Decision to investigate VC
Initial WS at Siemens
Scope for Pilot
decided
Second WS at Siemens
Pilot report out
Working methods
Internal VCC Pilot
13Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Vitual Commissioning pilot scope & findingsscope: Small ”simple” station Evaluate Siemens technical solution Start develop methods and workflows Suggest next steps
tech: ABB IRC5 Spot-servo and Handling/Glue Siemens CPU 319F Process Simulate & TiaPortal Simatic Net OPC Server
Findings: No adaptions needed for PLC or Robotics Very powerful debugging Easy, fast setup
Must C the need for: Commonality -> support auto generation Co-locate -> create understanding Co-operation -> responsibility split (VCC/Linebuilder)
14Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Virtcom research project
15Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
virtcom work packages
16Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Current activities new car projectscope: 2 stations for 2 model introductions Process Simulate connected via OPC or Simba Reviews during project to track progress VC presented before installation activities start Safety NOT a demand
Modified hand-over to supplier: Event based simulation instead of Gantt Charts Equipment with behavior models instead of simple
kinematics Think about and prepare for VC, reusable logics
Take more responsibility!
Measure success rate: Process related errors during commissioning Over all commissioning time of station Did we miss something? Preparation in early phases (more/less)
17Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
other activities input generation
scope: Focus on the input to Virtual Commissioning How much can we auto-generate?
POC study:Project together with EPLANUse information from process planning software to generate: Electrical schematics I/O lists
Start with respot stations in Q3 2015
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19Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group
Thank you!