productionplanning@bertrandt - usecases · 2020. 9. 1. · mtm uas assign the process steps to the...

ProductionPlanning@Bertrandt - UsecasesPresentation of CoC Production PlanningSept 2020, Dr. Michael Brodmann

ProductionPlanning@Bertrandt Usecases | Sept20 | MB

Bertrandt at a glance

Bertrandt established

Approx. 13,600employees

More than 50 sites inEurope, USA, China

Total revenues FY 2018/19approx. EUR 1 billion

Main shareholdersPorsche 28.97%

Boysen 14.9%

Development services – from the initial idea to series production

Production planning – from the initial idea to series production.

"Design and optimization of factory processes as well as planning, commissioning and series support for manufacturing plants, tools, devices, machines and special machines for the

production of vehicles / aircraft and their components as well as industrial products under the premises of digitization."



Plant planning & engineering

Supplier management

Process planning & optimization

Quality management

Digital factory

ProductionPlanning@Bertrandt | Sept20 | MB

sense analyse act

implementation

• Process data aquisitionaccording to planningspecifications (CLIFE)

• smartification

• Process analysis persuant to target values• Process consulting

• Process optimization bymeans of digital factory(simulation methods)

• Plant planing• Process planning• SCM (logistics planning,

supplier management)

• Monitoring of realization• Ramp-up support

• Quality management(process validation)

optimization

Time to marketOutcomeProcess stability

Benefit to …


CLIFE Digital Twin SolutionCloud Live Integrated Factory Environment


CLIFE connectivity modules enable data aggregation from industrial connectors like

MQTT or OPC, business intelligence connectors like REST or SOAP and BAPI or from PTC

ThingWorx.

DATA AGGREGATION &

AGGLOMERATION

MICROSOFT AZURE CLOUD

DATA PREPARATION & PREDICTION

CLIFE’s connectivity hub, the load balancer and its database is located in the MS Azure cloud.

The data is validated in the cloud and gateways for visualization and analytics are provided.

Use CLIFE extensions modules such as data analysis, machine learning or production

planning to optimize processes and evaluate the shop floor.

CLIFE ARCHITEKTURDepending on the customer needs, the CLIFE Digital Twin Solution is composed of

particular modules. The heart of the system is the CLIFE Basic Module (CBM). For data aggregation, CLIFE offers a wide range of connectivity modules (CCM), which gather

data, e.g. from OPC UA, SOAP or even PTC ThingWorx. Finally, several extension modules (CEM) offer additional analytic and prediction functions.


Our solutions for…

Supply chain management Supplier nomination Supplier selection Supplier qualification Technical supplier support Supplier tracking Procurement

Virtual validation (product and process) Material flow simulation Virtual commissioning PLC programming Robot simulation Offline/online programming Ergonomics simulation

Industrialization Simultaneous Engineering Plant concept development Plant construction

(mechanical, electrical, pneumatic systems) Simulation Technical documentation

Horizontal spiegeln

Production planning Automation Industry 4.0 Logistics planning

(in-house, inbound, outbound) Industrial engineering Workplace evaluation and optimization

Requirements management Maturity level assurance Reference point system (RPS) concepts Inspection characteristics planning Process quality Component quality


Selected references

Bounded supplier management Purchase part management -

sheet metal parts Purchase part management - piping

Virtual assembly of of a measuring cell Feasibility study for automated assembly of

attachment parts Material flow simulation for optimization

production, supermarket and assembly

electronic quality process for assembly and paint shop

Quality Planning Body-in-white purchase components

Matching management from pre-series phase to series production

Plant planning assembly rear axleactuator

Relocation of welding group production Body-in-white engineering rear door l/r

Concept development interferometerassembly site

Planning manufacturing processes for HV battery systems

Logistics concept planning for new production site (body and assembly shop)


Plant planning assembly rear axleactuator

Relocation of welding group production Body-in-white engineering rear door l/r

Concept planning Collecting and structuring the planning proposals, under the following aspects:

interfaces, number of derivatives and data analysis Develop 3 concept layouts due to automation level, flexibility, feasibility,

investment, TCO and scalability Create budget estimations for 3 developed concepts

Detail planning Create complete process flow and a detail working sequence for each station Calculate the operative time each assembling operation or section according to

MTM UAS Assign the process steps to the resources (labour resources, stations, product

components, equipment and material) Planning labour resources, creating detail layout

Preparation functional requirements and bill of materials Conform des purchase process, especially definition of the responsibility under

the condition of RASIC-charts between contractor and the buying department of the customer

Define the equipment package

Concept planning assembly plant rear axle actuator


Tier 1 automotive

Project team: 4 employees

12 months

Concept planning assembly

WP 1: Project leading, project management, and project controlling Documentation of the requirements for the relocation Scheduling disassembly of the non-functional production components (weeks,

daily time schedule) Overview of the relocation perimeters Layout planning (KD-area) inspection, documentation

WP 2: Planning relocation for the body-in-white production Complete bidding documents (master lists, drafts) Suppliers conventions, supplier assessment Mentoring suppliers during disassembly and set-up Regulating suppliers for completion on schedule

WP 3: Coordination of implementation and measurements tracking fortarget accomplishment regarding relocation

Dismantling by the nominated supplier of the existing production plant and its relocation

Tracking measures and defects reduction Restoration of production areas at Audi

Relocation production welding group


OEM automotive

Project team: 1 employee

18 months

Successful relocation planning

Engineering partner for the complete project rear door Concept planning and detail planning Digital factory Process Designer / Process Simulate Detail design equipment – CATIA V5 Availability simulation – Plant Simulation Create offline-programming Ramp-up management Documentation incl. operating instruction

Body-in-white production engineering rear door L/R


OEM automotive


6 months

Engineering Cells


Concept development interferometerassembly site


Logistics concept planning for new production site (body and assembly shop)

Concept development interferometer assembly site

Creation of specifications Idea phase

Collecting and structuring the requirements; Collection of ideas and creation of simple 3D models for validation and verification in the given installation space

Concept phase Concept selection and definition, validation and verification in cooperation

with the selected suppliers Creating and elaboration of the specifications in close coordination with Zeiss

and the selected suppliers

Supervision of the elaboration and implementation Detail phase

Supplier mentoring, supporting and coordination As interface function between Zeiss and suppliers

Elaboration phase Quality assurance and supplier support

Implementation phase Coordinate and support installation and logistics Approval and coordination

Tier 1 semiconductor industry


12 months

From concept to implementation



Increasing efficiency and planning the manufacturing processes as part of a prototype production of HV battery systems with dynamic tools and methods of digital factory

Determination of the process sequences for the installation of an HV battery Conception and selection of equipment Drafting of a production layout to implement production in existing structures Interpretation of automated robot cells for testing production-related contents as

part of prototype production Creation of a process simulation with “Plant Simulation” to validate the

production layout Execution of simulation experiments to quantify complex issues Development and maintenance of a three-dimensional representation of the

simulated production layout as a communication platform and decision-making basis for planning OEM automotive


16 months / 8 months

Increasing planning quality / security and ensuring planning processes


Logistics planning for body-in-white production and assembly shop

Planning of all inbound and in-house processes across multiple scenarios(relocation, changeover driving modes, straight driving modes and integration of Spyder models)

Layout planning for incoming and outgoing goods, picking areas, supermarkets and the material positioning on the line

Planning and documenting all relevant logistics processes Planning the goods receipt based on lock allocation and unloading time Driving schedule creation of all relevant suppliers Coordination with external interfaces such as external warehouses and suppliers Implementation and monitoring of planning with operational logistics

OEM automotive

Project team: 1-3 employees

31 months

Development logistics conceptfor body/assembly shop



Virtual assembly of of a measuring cabinet Feasibility study for automated assembly of

attachment parts Material flow simulation for optimization

production, supermarket and assembly

Virtual assembly of a measuring cabinet

Simulation of the assembly sequence of 14 modules Standardisation and optimization of workflows with Siemens Tecnomatix

Process Designer / Process Simulate Implementation and structure of already converted data Setting up the database and the eM-Server’s with test-schemes Compilation of prepared modules Developing simulations and DMU-studies on the scope of products and

resources Digital Mock-Up support on planning dates Allocation and positioning of equipment in the order of assembly



12 months

Development, kinematics and simulation of the assembly

to optimize workflows


Feasibility Study for Automated Assembly of Attachment Parts

Actual recording of manual attachment process of the hood, hatchback and fenders

Process analysis of the automatic – doors – attachment-parts-band (ATA) Development of various automation solutions regarding the mounting

variants and the mounting sequence Evaluation of the concepts based on technical and financial criteria Detailed planning of the solution approach with related departments Fender attachment: feasibility study in VSC, tolerance chain research Documentation and implementation with planning tools of digital factory

OEM automotive

Project team: 1 project leader

3 months

Concept for automatic assembly ofattachment parts


Simulation and optimization for production, supermarket and assembly

Project scope Simulation and optimisation of production, supermarket and assembly in

partial models and as an overall model

Project content Optimisation of performance output by determining the optimal number of

work piece carriers Bottleneck analyses and batch size optimisation Examination of optimal control strategies for the material flow Capacitive design of the supermarket and development of optimal ordering

behaviour Production planning:

Layout-optimisation (material flow) Mediation of system understanding

OEM automotive


16 months

Simulation and optimization production, supermarket and assembly



Bounded supplier management Purchase part management -

sheet metal parts Purchase part management - piping


Bounded supplier management

Process recording and detailed description of specialist field or section-specific fields of action (RACI, LIPOK)

Mapping of the process steps in time sequences and transfer of the process landscape into the proactive schedule planning

Continuous linking of process steps and schedule planning in the complete schedule (critical path, cross-departmental)

Creation of a consistent complete schedule with cross-plan networking Continuous optimization of delivery quality and reduction of purchase costs Bounded project and schedule planning across different hierarchy and reporting

levels

div. OEMs and Tier 1/2


4 years

Transparent supplier management


Purchase component management – sheet metal

Technical experts for the areas of tooling, body-in-white systems, gauges and measurement systems for technical evaluation of equipment

Evaluation and plausibility check of tooling methods, drawing simulations, operational sequences, plant concepts, jig designs, as well as the design of gauges and measurement systems

Recognize early risks and make recommendations to the supplier to ensure quality ramp-up

Implementation of change management and procedure management Monitoring the process of product and process optimization, and the

interactions till the component achieves quality level “Note 1” Supplier assessments based on ISO 9001/16949

div. OEMs and Tier 1/2


48 months

Purchase part managementand qualification


Pipe routing

Project planning, schedule planning, supplier management Participation in regular events and organization for coordination appointments

with R&D, customers and suppliers to achieve goals Achieve cost, schedule and quality goals Analysis, evaluation and tracking of suppliers Documentation of project progress and reporting to management from LR-Pure Planning and implementation of new processes in development

Capacity planning Schedule planning Project planning



6 months

Deliver „ready for mounting“ piping systems under the criteria „gas and water“ to the customer


electronic quality process for assembly and paint shop

Quality Planning Body-in-white purchase components



Electronic quality process for assembly and paint shop

Plant integration for digital production using an electronic quality processes Actual manufacturing process(SW application: ARIS) Target-process definition with new technology (digital devices in production) Rollout

Hardware-/Software-Implementation (500 tablets; 150 base stations) coordination of suppliers Launch management

Qualification of more than 8000 production employees Training concept Training organisation Training delivery

Elaboration of emergency strategies Building and testing of new technologies (e.g. RFID)

OEM automotive


4 years

Introduction of electr. quality process toreplace the vehicle test card

in the assembly and paint shop


Quality planning body-in-white purchase components floor assembly / headboard

Qualification and sampling of large assemblies (Floor assembly, front-end, rear-end, center-floor, A-pillar, CUV)

Quality monitoring of the individual components by suppliers Participation in sampling tests at individual components level, as well as partial

tables including print image approval in connection with press part planning Controlling loop 1-3 definition and monitoring Participation in SE / AG appointments Measuring point planning in connection with functional dimension tracking Masterbock shop of critical components PIK workshop for upgrading the facilities Complaint management on site Status reports regarding delivery quantity and quality

OEM automotive


32 months

Timely qualification of the components



Processing and monitoring of all quality tasks in complex single parts and assembly projects

Contact person for customers, suppliers and internally for quality issues Planning inspection concepts, creating inspection plans Creation of quality documents

(FMEA, production control plan, inspection plan, etc.) Analysis of components for quality-related issues Planning and acceptance of the equipment Sampling from suppliers Component sampling to customers Preparation and handover to series production departments at the end of the

project Special project with 1 employee: Complaint management

Tier 1 automotive


24 months

Quality assurance in the pre-series phaseand transfer to series production

What can we do for you?

Dr. Michael BrodmannHead of DepartmentProduction Planning

Tel.: +49 7132 386-370Cell phone: +49 151 12281653

[email protected]

www.bertrandt.com

Bertrandt Ingenieurbüro GmbH,Friedrich-Gauss-Straße 5, 74172 Neckarsulm


productionplanning@bertrandt - usecases · 2020. 9. 1. · mtm uas assign the process steps to the...

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