sustainable manufacturing systems rd program third edition jan 2010

8/13/2019 Sustainable Manufacturing Systems RD Program Third Edition Jan 2010

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2020 Sustainable Manufacturing Systems Capable of ProducingInnovative Environmentally Friendly and Safe Products

Third EditionJanuary 2010

R&D program proposal to secure competitivevehicle and powertrain production in Sweden

2020 Sustainable Manufacturing SystemsCapable of Producing Innovative

Environmentally Friendly and Safe Products

Swedish Automotive Manufacturing R&D Cluster Swedish Automotive Industry Needs of Manufacturing R&D 2010-2020 Continuity and change requirements for global competitiveness


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Table of contents

PageSammanfattning ________________________________________________ 4Executive Summary ______________________________________________ 61. Introduction__________________________________________________ 82. The Swedish Automotive Manufacturing R&D Cluster __________________ 93. Needs of Automotive Manufacturing R&D 2010-2020 _________________ 11

3.1 Vision, overall needs and goals ______________________________________ 113.2 Component Manufacture____________________________________________ 13

3.2.1 Manufacturing systems for components in future powertrains ___________________ 143.2.2 Environmentally adapted manufacturing processes____________________________ 153.2.3 Realistic verification of manufacturing processes______________________________ 163.2.4 Manufacturing of lightweight, strong and energy efficient components ____________ 183.2.5 Development of competitive production lines with the right level of flexibility, capacityand capability. _____________________________________________________________ 193.2.6 Quality control preparation and non-destructive measurement online _____________ 20

3.3 Body & Cab ______________________________________________________ 213.3.1 New advanced lightweight and very thin conventional sheet materials ____________ 223.3.2 New cost and lead time efficient die manufacturing concepts ____________________ 223.3.3 New forming and joining methods _________________________________________ 233.3.4 New, alternative or improved equipment for forming, joining and quality assurance__ 233.3.5 Forming and joining simulations with improved prediction accuracy_______________ 243.3.6 2020 Sustainable press shop and body shop for manufacturing of innovative bodies andcabs _____________________________________________________________________ 24

3.4 Surface Treatment & Paint __________________________________________ 243.4.1 Future process material for the next generation surface treatment of vehicles with newcombined material __________________________________________________________ 253.4.2 Process enhancements for reduced environmental impact ______________________ 263.4.3 The Virtual Paint Shop __________________________________________________ 263.4.4 Surface Treatment Application Center ______________________________________ 27

3.5 Assembly _______________________________________________________ 283.5.1 Support of innovative product developments ________________________________ 283.5.2 Process development / automation ________________________________________ 293.5.3 People in production____________________________________________________ 303.5.4 Visualization __________________________________________________________ 30

3.6 Geometry and Quality______________________________________________ 313.6.1 Definition of demands regarding geometrical qualities _________________________ 313.6.2 Methods of working for a geometry assured process___________________________ 323.6.3 Cost models for quality deficiencies________________________________________ 323.6.4 Improved verification techniques__________________________________________ 32


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3.10 Virtual Engineering and Manufacturing Data Management. ________________ 423.10.1 Management of production related data ___________________________________ 443.10.2 Multidisciplinary change management _____________________________________ 453.10.3 Improved utilization of Virtual Manufacturing Engineering tools _________________ 453.10.4 Simulation of production system _________________________________________ 46

3.11 Education ______________________________________________________ 463.11.1 Competence and education matrix________________________________________ 47

4. Identified competencies within universities and institutes and globalcompetitiveness________________________________________________ 48

4.1 General remarks __________________________________________________ 484.2 Component Manufacture____________________________________________ 494.3 Body & Cab ______________________________________________________ 504.4 Surface Treatment & Paint __________________________________________ 514.5 Assembly _______________________________________________________ 514.6 Logistics & Material Handling/Planning ________________________________ 524.7 Production Management____________________________________________ 524.8 Virtual Manufacturing Engineering and MDM ____________________________ 53

5. Continuity and change requirements for global competitiveness _______ 546. References __________________________________________________ 56Appendix 1 Cluster members ____________________________________ 58


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Sammanfattning

Trots sina tidigare framgngar, gr svensk fordonsindustri stora utmaningar till mtesunder de kommande 10-20 ren. De frmsta drivkrafterna bakom de kommandefrndringarna r marknadsrelaterade, strukturella/ekonomiska, lagkravsbaserade samtteknologiska .

Det kande antalet modeller och varianter och den allt kortare produktlivscykeln har enstor inverkan p investeringskostnaderna och kostnaden per tillverkat/slt fordon. Nyadrivlinor kommer att ka antalet komponenter och varianter ytterligare.

Fr att bibehlla konkurrenskraften (m a p kostnadsniv) mste fordonsfretagenfrbereda sig s att de i framtiden kan producera bde fordon som drivs konventionelltoch fordon med alternativa drivlinor i samma produktionssystem.

Underleverantrer str fr ca 60-75% av vrdet av ett nytt fordon. Ett gott samarbete(inte minst inom forskning och utveckling) mellan fordonsfretagen och under-leverantrerna r av avgrande betydelse fr vr gemensamma konkurrensfrmga.

Samarbete inom produktionsteknisk forskning och utveckling (FoU) och offentligfinansiering av samarbetsprojekt inom produktionsteknisk FoU r av stor betydelse, nrdet gller att strka och vidareutveckla svensk fordonsindustris globala konkurrenskraft.

Svensk fordonsindustri har drfr bildat ett kluster fr samverkan inomproduktionsteknisk FoU. Detta kluster bestr i sin tur av 10 delkluster enligt Fig. 1.

Swedish Automotive Manufacturing R&D Cluster

Component

Manufacture

Surface

Treatment

& Paint

Ass embl yBody & Cab

Manufacture

Aut omatio n of

Strategy Governance Board

Operative Management Group


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Vra ml r att vsentligt bidra till att

reducera utslppen av fossilt CO2 och vriga emissioner frn skra vgfordon ocharbetsmaskiner genom att skapa frutsttningarna fr tillverkning av innovativamiljvnliga och skra produkter.

reducera alla frluster vid tillverkningsberedning och markant reduceratillverkningsprocessernas miljpverkan. Detta bland annat (hdanefter bl. a.) genomen kraftigt kad anvndning av virtuella verktyg fr t. ex. snabba och noggrannakonsekvensstudier och tillverkningsoptimeringar.

Uppfyllandet av ovan nmnda ml anses strka och vidareutveckla svensk fordons-

industris konkurrenskraft.

Freliggande FoU-program frvntas vsentligt bidra till att uppn fljandeProduktrelaterade ml 2010-2015: uppfyllandet av produktkraven m a p lgre vikt och kad passiv skerhet som i sin tur

krver nya eller frbttrade material och tillverkningsprocesser, en snabbt kad anvndning av verktyg fr virtuell tillverkningsberedning i syfte att

utfra snabba och noggranna konsekvens- och optimeringsstudier, kad tillverkningsflexibilitet och framtagning av seriestorleksanpassade

tillverkningslsningar i syfte att markant ka tillverkningsprocessernas och -systemenshllbarhet.

tillverkning av fordon med konventionella och nya drivlinor i samma produktions-system.

Vidare frvntas programmet vsentligt bidra till att uppn fljande ml inomTillverkningsberedning och Produktion: 40% hgre produktivitet i tillverkningsberedning (bl. a. med hjlp av virtuella

beredningsverktyg). 30% hgre produktivitet i produktionsprocesserna. 30% mindre miljpverkan i tillverkningsprocesserna.

Den svenska fordonsindustrin agerar p en konkurrensutsatt global marknad. Det rdrfr av stor vikt att dess svenska FoU-partners ocks r kapabla att konkurrera psamma globala marknad.

Fr att skra en mer effektiv anvndning av vra gemensamma resurser pgr enkontinuerlig en dialog med universitet och hgskolor (speciellt Produktionsakademin) ochinstitut. Syftet med denna dialog r att tillsammans bestmma hur vi gemensamt brbygga upp "kritiska massor", undvika dupliceringar, strka och vidareutvecklaexisterande kompetenser fr att strka universitets, hgskolors och instituts globalakonkurrensfrmga inom produktionsteknisk FoU.


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Executive Summary

In spite of its successes, the Swedish automotive industry faces great challenges duringthe coming 10-20 years. The major drivers for change are market related,structural/economic, regulatory and technological.

The increasing number of models and variants and the shortening product life cyclesimpose a large impact on the investments costs and cost per manufactured/sold car or

vehicle. New powertrains will increase the number of components and variants.To be competitive (with respect to costs) it is imperative that necessary preparations aremade so that the industry is capable of producing both conventional and different typesof new powertrains in the same production system.

With an average of 60-75% of the value of a new vehicle being contributed by suppliers,the relationship (not least a R&D collaboration) between the vehicle manufacturers andtheir supply chain is critical for competitive survival.

Collaborative Manufacturing R&D and public funding of collaborative Manufacturing R&Dare of great significance to strengthen and develop the global competitiveness of Swedishautomotive manufacturing. Increased R&D collaboration is required both within theindustry and between the industry and universities and institutes.

The Swedish automotive manufacturers have therefore created a Manufacturing R&DCluster, Fig. 1.


Component

Manufacture

Surface

Treatment

& Paint


Manufacture




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systems must be able to produce these innovative products at reasonable costs, withhigh quality and shorter order to delivery time.

Our targets are to significantly contribute to the reduction of emissions of fossil CO2 and other emissions from safe vehicles and construction

equipment by creating the pre-requisites for manufacturing of innovativeenvironmentally friendly and safe products,

all losses in Manufacturing Engineering and significantly decrease the environmentalimpact of the manufacturing processes. A strongly increased use of virtual tools forrapid and accurate consequence studies and manufacturing optimizations is held to beof great importance in this context.

Achievement of the above-mentioned targets is believed to strengthen and furtherdevelop the competitiveness of the Swedish automotive industry.

The present R&D program is expected to significantly contribute to achievement of thefollowing product related targets in coming decade: Fulfillment of the product demands such as lower weight and increased passive safety

which require new or improved materials and manufacturing processes. A rapid increase in use of tools for Virtual Manufacturing Engineering to conduct rapid

and accurate consequence and optimization studies. Increased manufacturing flexibility and creation of volume size dependent

manufacturing solutions to significantly increase the sustainability of themanufacturing processes and systems.

Manufacturing of vehicles with conventional powertrains and vehicles with new typesof powertrains in the same production system.

To ensure more efficient use of resources, we have a continuous dialogue with the

universities, particularly with the Swedish Production Academy and institutes. Thepurpose of this dialog is to decide how we jointly should proceed to build up a criticalmass, avoid duplication, and strengthen and further develop the existing competencies toincrease the global competitiveness of the universities and institutes withinManufacturing R&D.


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1. Introduction

The Swedish automotive industry (Volvo Cars, Scania, AB Volvo, Saab Automobile andtheir Swedish suppliers) employs more than 100 000 people Each job in manufacturingis, on average, linked to two to three jobs in manufacturing related services, Totally,every tenth Swede earns her/his income from motorism, [1, 2, 3].

The Swedish export of passenger cars, trucks, buses and components/spare parts was

worth an all time high 160 billion SEK during 2007/2008. This amounted to almost 15%of Sweden's commodity export. [4]

In spite of its successes, the Swedish automotive industry faces great challenges duringthe coming 10-20 years. The major drivers for change are challenges regardingenvironmental footprint, global competition and regulatory issues.

The increasing number of models and variants and the shortening product life cyclesimpose a large impact on the investment costs and cost per manufactured/sold vehicle.

Competition has increased with the globalization of the industry. The sector is challengedby manufacturers in other European countries, US and Japan, with South Korea, China,India and others not far behind. In their initial development phase, each of these Asiancountries has been or is able to compete on price, at least temporarily. [5, partially].

Cost also increases as a result of multiple emergent technologies, requiring management,engineering input and investments in product and manufacturing development. Theseincludes hybrids, fuel cells, latest generation of petrol and diesel, aluminium and carbonfibre structures, new powertrains and transmissions, electronics in vehicles, intelligentvehicles and highways, pedestrian protection, etc. [5, partially].

With an average of 60-75% of the value of a new vehicle being contributed by suppliers,the relationship (not least a R&D collaboration) between the vehicle manufacturers andtheir supply chain is critical for competitive survival, [5, partially].

Globalization, particularly international trade, has been the single most important

component behind the Swedish economic growth during the past 150 years. Globalizationconstitutes a fantastic opportunity for progress in Sweden and the rest of the world, [6].However, it puts demands on different actors, among them the parties involved inautomotive manufacturing R&D in Sweden. An efficient use of national R&D resourcesrequires an efficient collaboration and role distribution between industry, academia andpublic financiers.


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2. The Swedish Automotive Manufacturing R&D Cluster

The Swedish automotive industry has created 10 clusters 4 clusters working with theissues that concern the sequential automotive manufacturing process and 6 clustersdealing with the transverse issues affecting all manufacturing sub-processes. See Table1.

Table 1. The Manufacturing R&D Needs Identification is conducted within these clusters.

Component Manufacture

Body & Cab Manufacture

Surface Treatment &

Paint

Assembl y

Sequential main automotive

manufacturing processes

Transverse processes affecting all main manufacturing processes

Geometry &Quality

Automat ion

of

Production

Lines,

Robotics

&

ControlSystems

Logistics &

MaterialsHandling

Virtual

Engineering

&MDM

ProductionManagement Education

Each cluster comprises representatives from the automotive companies (incl. FKG), withone of these representatives acting as cluster leader. These clusters are continuouslyreviewing the research needs in each specific area. The programmatic needs described inthe present report are based on the work conducted by these clusters.

Sweden's R&D resources are relatively limited. It is important that these scarce resourcesare used efficiently. The Swedish Automotive Manufacturing R&D Cluster has therefore anongoing dialogue with the academic partners to jointly find a way forward to maximizethe efficiency of the national R&D structure. Each cluster also has, in addition to theindustrial leader, a coordinator coming from a university or institute


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Component

Manufacture

Surface

Treatment& Paint


Manufacture

Production

Management

Aut omatio n of

Production Lines,

Robotics &

Control Systems

Geometry & Quality Education

Virtual

Engineering &

MDM

Logistics &

Materials

Handling



Fig. 2. The Swedish Automotive Manufacturing R&D Cluster is led by a Strategy Governance Board

and an Operative Management Group.

We welcome all manufacturing-related initiatives aiming at strengthening and developingthis competitiveness (and see the establishment of the Swedish AutomotiveManufacturing R&D Cluster as such an initiative) and are open for co-operation withthese initiatives. We also welcome other companies to work together with the automotivecompanies.


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3. Needs of Automotive Manufacturing R&D 2010-2020

3.1 Vision, overall needs and goals

Our vision is to explore, find, specify and create the pre-requisites for establishment of"2020 Sustainable Manufacturing Systems Capable of Producing InnovativeEnvironmentally Friendly and Safe Products".

Creation of innovative Environmentally Friendly and Safe products is essential to

preserve and strengthen competitiveness. At the same time, the manufacturing systemsmust be able to produce these innovative products at reasonable costs, with high qualityand shorter Order to Delivery Time. From today's perspective, and considering thecurrent development, three major areas are identified as most significant for creation ofinnovative products:

Introduction of new advanced materials both on the market and in the automotivemanufacturing processes.

Rapid increase in development of virtual tools and application of virtual engineering,

particularly virtual manufacturing engineering. Development of new powertrains in the automotive sector. It is assumed that in 2020

the manufacturing system will have to be able to deal with a mixture of differentmodels and powertrains, Fig. 3. This implies that the number of product variants isexpected to increase dramatically. This might also mean that the series sizes willdecrease significantly.

Presumptions for Swedish Automotive ManufacturingPresumptions for Swedish Automotive Manufacturing

New Power TrainsNew Power Trains : Hybrid/Plug: Hybrid/Plug--in/Fuel cellin/Fuel cell


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Ability to make several product models including variants with alternativepowertrains (includes also bodies and cabs for new powertrains) in the same

production system or in the same so-called line. High availability (24 hours, 6 days per week). High quality. High productivity. Reasonable manufacturing costs. Shorter order to delivery time. Mass customization.

Our targets are to significantly contribute to the reduction of emissions of fossil CO2 and other emissions from safe vehicles and constructionequipment by creating the pre-requisites for manufacturing of innovative

environmentally friendly and safe products, all losses in Manufacturing Engineering and significantly decrease the environmental

impact of the manufacturing processes. A strongly increased use of virtual tools forrapid and accurate consequence studies and manufacturing optimizations is held to beof great importance in this context.

Achievement of the above-mentioned targets is believed to strengthen and furtherdevelop the competitiveness of the Swedish automotive industry.

The present R&D program is expected to significantly contribute to achievement of thefollowing Product related targets 2010-2020: Fulfillment of the product demands such as lower weight and increased passive safety

which require new or improved materials and manufacturing processes. A rapid increase in use of tools for Virtual Manufacturing Engineering to conduct rapid

and accurate consequence and optimization studies.

Increased manufacturing flexibility and creation of volume size dependentmanufacturing solutions to significantly increase the sustainability of themanufacturing processes and systems.

Manufacturing of vehicles with conventional powertrains and vehicles with newenvironmentally friendly powertrains in the same production system.

The present R&D program is, furthermore, expected to significantly contribute toachievement of the following Manufacturing Engineering and Production related targets: 40% higher productivity in Manufacturing Engineering (by, for instance, extensive use

of virtual tools) 30% productivity increase in the production processes. 30% lower environmental impact in the manufacturing processes.

The R&D needs specified in the following sections are identified in accordance with theproduct and manufacturing attributes used as new products and processes are designed


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Product and Manufacturing AttributesProduct and Manufacturing Attributes

Attr ibutesAttr ibutesInnovativeInnovative

EnvironmentalEnvironmental

SafetySafetyQualityQuality

ConvenienceConvenience

Driving ExperienceDriving Experience

Attractive Design/StylingAttractive Design/Styling

LeadLeadTimeTime efficientefficient



Safe, healthy, motivatingSafe, healthy, motivatingFlexible (variant, volume)Flexible (variant, volume)

ChangeChange--over efficientover efficient

Capable/QualityCapable/Quality

Lead time efficientLead time efficient

Cost efficient/ProductiveCost efficient/Productive

Robust/ReliableRobust/Reliable

ProductProduct ManufacturingManufacturing

Product and Manufacturing AttributesProduct and Manufacturing Attributes



SafetySafetyQualityQuality

ConvenienceConvenience

Driving ExperienceDriving Experience

Attractive Design/StylingAttractive Design/Styling

LeadLeadTimeTime efficientefficient



Safe, healthy, motivatingSafe, healthy, motivatingFlexible (variant, volume)Flexible (variant, volume)

ChangeChange--over efficientover efficient

Capable/QualityCapable/Quality

Lead time efficientLead time efficient

Cost efficient/ProductiveCost efficient/Productive

Robust/ReliableRobust/Reliable

ProductProduct ManufacturingManufacturing

Fig. 4. The needs are specified based on the products and manufacturing attributes commonly usedat OEMs.

3.2 Component Manufacture

This area is dependent upon the following technology areas:

Feature based component design for robust and productive manufacturing processes. Material development, including manufacturing of new high performance and

environmentally sound materials. Process planning to be able to select the optimal production method and equipment. Operations planning as NC, Industrial Robots and CMM-programming, education and

preparation of work instructions. Design and manufacturing of tools for machining, clamping and quality control. Simulation, evaluation and optimization of processes. Shaping processes as casting, forging and sintering.


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Shorter lead-time in the introduction of new products and shorter ramp-up time

Competitive manufacturing in a global perspective with higher efficiency and

productivity. Manufacturing systems with ability to handle an increased number of variants and

new types of products in a rational way

Competence development: There is a need for education programs in industry andtechnical schools at all levels related to the new technologies. Every projectshould consider the need of education and technology transfer materials. This willbe done in collaboration with the education cluster.

The following programmatic needs are identified:

3 . 2 .1 M a n u f a c t u r i n g s y s t e m s f o r c o m p o n e n t s in f u t u r e p o w e r t r a i n s

Attributes: Innovative, Environmental, Safe, Healthy, Flexible, Capable, Costefficient/Productive, Robust/Reliable

Description:

We urgently need to increase the R&D-efforts to develop manufacturing systems forcomponents in future power trains.

Identified R&D areas are:

1) New Products require new components: Component manufacturers need todevelop new manufacturing systems to be able to produce new components for:

Low weight, high speed electrical engines New batteries with better performance High performance transmissions. Downsized combustion engines optimized for hybrid and multi fuel power trains Components for Hybrid Power Trains

2) Component manufacturing systems capacity and capability:There will probablybe a lack of necessary components on the market. Future suppliers must be identifiedand encouraged to develop appropriate knowledge and resources many years before

actual use to be able develop and manufacture the demanded components. We needto identify the strategic components in Hybrid Power Trains that could be suitable formanufacturing in Sweden.

3) Rapid and complex change over:What problems will arise when trying to produceelectric engines in a factory built for combustion engines? Main Power Trainmanufacturing concepts need to be replaced by something completely different This


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Swedish automotive manufactures should be well prepared to fulfill the demandsfrom climate, climate regulations, increased oil prices and customers in acompetitive way.

Swedish suppliers of components shall be well positioned to meet the newdemands from the automotive industry.

Sweden should be judged as one of the world leaders in electrified and hybridvehicle design and manufacturing.

3 . 2 .2 En v i r o n m e n t a l ly a d a p t e d m a n u f a c t u r i n g p r o c es se s

Attributes: Safe, Energy Efficiency, Environmental, Cost efficient/Productive,Robust/Reliable

Description:One of the key aspects in future component manufacturing is the implementation ofimproved technologies that minimize the impact on environment and health inside andoutside the factory.

This area covers the following areas of component realization: casting, forging, surfaceand heat treatment and machining.

Concerning machining, one example is the use of processing liquids (cutting fluids,cleaning, etc) in component manufacturing. We need new processing liquids withdecreased impact on environment and health and implementation of dry machining orminimum quantity lubrication for cutting operations where applicable. Environmentalaspects of chemicals used in connection to heat treatment are also of importance.Chemicals used are detergents, process gases and quenchants. Use of chemicals needsto be minimized, and environmentally sound alternatives are needed in many cases.Improved handling and treatment of residues from both the machining of components aswell as casting is important.


1. Implementation of environmentally adapted machining/grinding by use of new

cutting fluids and minimum quantity or dry lubrication for specific operations. Ofparticular importance is to have appropriate and standardized methods forassessment and verification of the performance of such liquids includingmachinability, health aspects, system aspects and environmental/health impact.

2. Environmentally sound and sustainable quenchants in heat treatment.Alternatives to mineral oils which are normally used today together with polymer

2020 S t i bl M f t i S t C bl f P d i


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actions to avoid soft spots, rework and scrap needs to be investigated anddeveloped. Cleanliness requirements need to be further developed.

6. Simulation and evaluation of the overall life cycle assessment (LCA) ofmanufacturing process chains from an environmental perspective.

Measurable goals / Wanted effects:

Manufacturing processes with minimal environmental impact.

Methods and tools for life cycle assessment (LCA).

Decreased costs for maintaining and using processing liquids.

Better knowledge regarding interaction between different process steps.

Practical experimental techniques for fast and predictable assessment of fluids.

Reduced energy consumption.

Reduced scrap runs.

3 . 2 . 3 R e a l i s t i c v e r i f ic a t i o n o f m a n u f a c t u r i n g p r o c e s s e s

Attributes: Capable, Cost efficient/Productive, Robust/Reliable

Description:New materials are enablers to further develop Power trains with less environmental

impact.Component manufacturing might in the future be the bottleneck in the lead time ofintroducing new products since product development is faster. The shortened lead-timesfor new projects, in combination with new material and designs for Power traincomponents will increase the need of methods and tools for virtual verification ofmanufacturing processes. This will lead to secured quality at start of production.

The core of virtual verification and manufacturing processes are realistic material models,

numerical- and process-knowledge. The research program will suggest and evaluatesuitable material models for the materials that will be prioritized.


The main challenges for material modelsare:

2020 Sustainable Manufacturing Systems Capable of Producing


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Application areas for manufacturing process verification

1. Casting Material Pouring Residual stresses after casting (also input to virtual verification of machining

process) Porosity, shrinkage Mechanical properties like strength, hardness, etc. Energy consumption

2. Machining process (Chip removal) Material properties of work piece (including influence from the process of the work

piece blank by casting or forging) and cutting material Interaction between work piece and cutting edge and the impact on surface

integrity. Forces from tools and clamping forces from fixture Stability of machine

Energy consumption3. Induction hardening

Material properties of work piece (including influence from the forged part as wellfrom the rough machining

Hardening depth Residual stresses and form deviation of the part during / after process Crack prevention Energy consumption

4. Case hardening, nitriding and nitro carburizing Material Furnace atmosphere Hardening depth (case depth) Residual stresses and form deviation of the part during / after process Crack prevention Energy consumption


Reduce lead time for introduction of new materials/ products / processes and lessenvironmental impact

Reduce time to ramp up to full capacity from start of production by virtuallyverified critical processes.



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3 . 2 .4 M a n u f a c t u r i n g o f l i g h t w e ig h t , s t r o n g a n d e n e r g y e f f i c i en t

c om p o n e n t s

Attributes: Capable, Environmental, Cost efficient/Productive, Robust/Reliable

Description:The components must be optimized regarding the ratio strength/weight to improveenergy efficiency and performance. New improved materials and processes have apotential for more weight efficient components.

In most cases the manufacturing process gives restrictions (or possibilities) on design

and product properties. We need improved product designs and manufacturing methodsin order to be able to produce weight efficient components.

In certain cases, the solution to lightweight and efficient components is throughcombination of different materials into one structure.


Fo r g i n g t o p i c s1) Improved design and optimization of blanks and forging tools for better productperformance.

2) Controlled gradients of properties.3) Near-net shape forming in order to minimize subsequent cutting.4) Zero-defect strategy to reduce scrap.5) Minimized consumption of material and energy.6) Controlled surface performance by shot-peening for improved durability.7) Influence of micro and macro segregations and material flow directions on shape

accuracy and performance

H e a t T r e at m e n t t o p i c s

1) Influence of heating and cooling on distortion.2) Optimized surface characteristics and performance.3) Influence of straightening techniques on fatigue properties.4) Control of mechanical properties after heat treatment.5) Optimization of residual stresses in order to optimize product performance.6) Combination of processes for improved component performance, e.g. induction

hardening/ double shot-peening or nitriding/nitro carburizing/induction hardening.7) Influence of surface contamination, e.g. cutting fluids, on process stability,

product quality and performance for chemical heat treatment processes.

Cu t t i n g t o p i c s



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8) Methods for minimizing burrs and methods for efficient deburring.

Surface integrity topics1) By reducing the topography of functional surfaces we can obtain rather

impressive improvements of the power that can be transmitted by thecomponents.

2) Decreased surface structure and form variation in component finishing:honing, grinding and polishing of e.g. gears, cylinder liners, cams, followersand bearings.

3) Decreased friction and wear in automotive components by tailor-made

engineered surfaces. Abrasive- and "non-conventional" finishing processes aswell as component coating technology.4) In process metrology of surface integrity factors: surface structure, form,

residual stresses, and hardness.

N e w a d v a n c e d m a t e r i a l s

1) Casting and machining of CGI (tailoring of material and casting process,process optimization with reference to component-like test object and real partmachining, in-depth studies of microstructure-machining-simulation,

environmentally adapted machining).

2) Machining of high strength steel and other advanced alloys (structure-machining-simulation incl. deformation behavior of tough/hard materials).Machining of case-hardened steel, nodular iron, heat resistant alloys and light-weight alloys, e.g. Aluminium, Magnesium and ADI regarding demandspecifications, simulation model for education, increased machinability andgeneral knowledge development. Combinations of different materials in joint

structures and components is special challenge for machining optimization.This area is expected to increase in importance in future.

Measurable goals/Wanted effects:

Reduced weight

Reduced energy losses in powertrains

Reduced energy consumption in manufacturing

Availability of environmental manufacturing alternatives Weight effective product performance

Improved process stability/-capability by robust manufacturing

Increased productivity



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g y p gInnovative Environmentally Friendly and Safe Products

that supports a reasonably fast and still reliable development process of manufacturingsystems with the right capability, capacity and flexibility.

Identified R&D areas are:Two main keys in such methodology are standardized work procedures and digital tools:

Standardized work proceduresclearly visualize what is required when developingnew flexible factories, reconfiguring existing facilities and deploying dynamic resourceallocation:

1) Work processes contain instructions and support for factory design and

production investments.2) Specific check lists and routines for achieving flexibility, such as

process planning of spare parts and plans for fast changes betweentools

Digital methods and toolsmake it easy to quickly test and verify alternatives:

1) A digital factory model infrastructure specifically to support the systemdevelopment. With such an infrastructure based on neutral formats, thereuse, and communication and sharing of models and data fromdifferent sources would be optimized.

2) Method for simulation and process planning to analyze and comparealternate solutions with respect to the capacity and degree of flexibilityof the production system.

3) Methods for reconfiguring manufacturing systems.

4) Digital verification based on realistic models of the productionresources.

5) Web-based manuals that support education as well as sharp projects.


Lead-time for process planning reduced by 20-40%

Time for trimming during installation of new system decreased by 50%

Scrap reduction by 15-30%

Lead time to purchase and install new machinery reduced by 30%. The number of unplanned disturbances reduced by 50%.

Ramp up time of new system after installation decreased by 30-40%

Total investment cost reduced by 20%

I d t t l d ti it b 5% b ti i ti



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Innovative Environmentally Friendly and Safe Products

The purpose of the area is to develop knowledge and methods for measurement of criticalprocess parameters inline. Examples of parameters:

Grinding burns cracks, blisters and surface quality in general. Geometric tolerances (Distances, diameters, radius, roundness, straightness) Hardness, residual stresses Layer thickness and cleanliness Microstructure, retained austenite and distortions

As a step after inline quality control the target is to develop full process control. Thismeans that we should control the process to meet the critical to quality features instead

of measuring them after the process. Inline process control will introduced for processeswhere the risks for quality losses are most critical like grinding of shafts and gears:


1) Development of quick response measuring techniques in the area where the speedof the inline control station must pace with the process cycle time.

2) Non-destructive measuring techniques and sensors with robustness to withstandcontamination from chips, cutting fluid, oil..

3) Deeper understanding of the applicability of techniques like eddy current, micromagnetic barkhausen, ultrasonic, X-ray and fluorescent methods.

4) Optical inspection methods (surface reflection) need to be scrutinized thoroughlyas they may provide a cost-effective alternative to other testing methods.

5) Develop more precise knowledge of the correlation between the processparameters and the feature that should be controlled

6) Development of sensors / measuring equipment to be able to measure and controlprocesses online.

Measurable goals / Wanted effects

Reduce production cost through decreased manual measuring

Reduced quality loss cost through improved process stability/capability

Reduced process-time

Increased quality through possibility to control the process to the optimum level.

3.3 Body & Cab

This area is dependent upon the following technology/competence areas:

l f

2020 Sustainable Manufacturing Systems Capable of ProducingI ti E i t ll F i dl d S f P d t


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Industrial IT: machine control system development Equipment: connected to new (new to our processes) forming, joining, machining and

geometry assurance technologies (otherwise no research & advanced engineeringneeds within this area)

The targets for the proposed R&D areas described below are:

Fulfillment of the product demands such as lower body/cab weight and increasedpassive safety which require new materials and processes.

Fulfillment of the styling demands which require more complex shapes, sharper radii,advanced joining methods, whilst new materials and processes are being introduced.

Production of different bodies/cabs for different types of power trains (conventionaland different grades of hybrids) in the same manufacturing system.

Development of volume size dependent manufacturing solutions. A significant productivity (including throughput) increase in the production processes. A significant productivity increase including lead time reduction in the product

development process (Manufacturing Engineering being a part of this process) withspecial focus on Manufacturing Engineering.

20% lower die investment costs and a significantly lower total investment costs. To describe how sustainable press shops and body shops should look like in 2020.

These press and body shops should be capable ofo producing innovative products.o managing the targets above.o being safe, ergonomically feasible, environmentally friendly and examples

of "good" manufacturing.

The following programmatic needs are identified:

3 . 3 .1 N e w a d v a n c e d l i g h t w e ig h t a n d v e r y t h i n co n v e n t i o n a l s h e e tm a t e r i a l s

Attributes: Environment, Safety, Quality

Description: Introduction (in products and production) of new advanced sheet materials,very thin conventional materials or tubes and extruded profiles requires a large numberof tests. Many of these tests involve forming and joining of typical parts which in turn aretested with respect to targeted properties. However, the basal tests could be carried out

in collaboration with other vehicle manufacturers and suppliers. In these basal tests,formability andjoinability of the new materials are tested. In some cases, it might benew environmentally friendly adhesives that need to be tested.

This is a never-ending activity and should be a part of all of the coming public researchand advanced engineering programs.



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or not, and different production volume scenarios. Currently, a running MERAproject deals with these issues. However, the work cannot be considered ascompleted when this running project ends.

Even though research projects have addressed these issues the last years thework cannot be considered as completed. There will be a further need for publicfinancing of research within this area for many years to come.

o Die manufacturing concepts

Description: Die manufacturing comprises many different phases (from die design

to casting, machining, assembly, quality control and documentation with manylogistics issues). All of these phases need to be studied and developed further. Apossible elimination of the casting pattern by using new direct casting methods orelimination of all manual work in die manufacturing have major impacts on costsand delivery precision. As volume size is decreasing, new die concepts are neededbased on the targeted production volume.This area has been neglected for many years, involves a large number ofcompetency areas and companies, and needs therefore to be incorporated incoming public funding programs.

3 .3 .3 N e w f o r m i n g a n d j o i n i n g m e t h o d s

Attributes: Environment, Safety, Cost reduction, Attractive Design, Quality

Description: New and improved forming and joining methods need to be tested andevaluated continuously. The industry needs information about what to think of as theparts are designed for the new forming or joining method, how the manufacturing

process should be outlined, what is required to simulate the process, how much one canrely on the simulation results, what type of equipment is needed, which productionvolume the new method is suited for,etc. In many cases, the target might be to explorethe capabilities of an improved method or to improve anexisting method.

The activities within this area could also be classified as never-ending and should beincorporated in all coming public funding programs.

3 . 3 .4 N e w , a l t e r n a t i v e o r im p r o v e d e q u i p m e n t f o r f o r m i n g , j o i n i n g a n d

q u a l i t y a s s u r a n c e

Attributes: Environment, Safety, Cost reduction, Delivery Precision, Flexibility,Quality



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3 . 3 .5 F o r m i n g a n d j o i n i n g s i m u l a t io n s w i t h i m p r o v e d p r e d i c t io n a c c u r a cy

Attributes: Environment, Safety, Cost reduction, Delivery PrecisionDescription: Forming simulations are used extensively today. However, introduction ofnew materials require new material models. The forming operation itself (for instance 3DRoll forming, Electromagnetic Forming or Hot Forming) might require testing andevaluation of different simulation techniques. Robustness studies are required to studythe impact of, for instance, the spread in the mechanical properties of the incomingmaterial and different process parameters.Joining simulations are not used as extensively today as forming simulations. There is a

large need for this type of simulation both to study a single joint and also theconsequences of, for instance, a spot welding scheme on the quality output andgeometrical conformance of subassemblies (virtual pre-matching).

Simulations need to be a significant part of all coming public funding programs.

3 . 3 .6 2 0 2 0 Su s t a i n a b le p r e ss sh o p a n d b o d y s h o p f o r m a n u f a c t u r i n g o f

i n n o v a t i v e b o d i e s a n d c a b s

Attributes: Environment, Safety, Cost reduction, Delivery Precision,Environment, SHE

Description: the requirements set on sustainable manufacturing systems (press shop andbody shop) capable of producing a large number innovative product variants (bodies forconventional vehicles, space frame designs and different types of hybrids, flexible & costefficient processes for shared platforms) need to be investigated in the light of energy

efficiency, layout affecting technologies (the emerging robotic and mechatronictechnologies, sensor technology, etc.), new materials, new forming and joining methods,new equipment (described above), and new geometry, quality and production controlmethods and tools.

3.4 Surface Treatment & Paint

This area is dependent upon the following technology areas:

Materials Technology (including paint, sealers, BIW materials) Corrosion: Accelerated corrosion bench tests which correlates to long-term corrosion

performance Paint Technology: Development of new paint technologies which can lead to reduction



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Develop process technologies which significantly reduce the energy use and simplifychange over to climate neutral energy sources

Develop process technologies which significantly reduce the environmental impact of

the paint process Develop process technologies enabling new corrosion protecting technologies which

reduce the operating cost for customers as well as environmental life cycle impact Develop manufacturing engineering tools which supports shorter development

process timing and reduces the necessity for physical prototype testing.

At paint application:

20% decreased material consumption 10% increased paint shop capacity Reduce solvent use in paint shop and a corresponding reduction of environmental

impact

In the pre-treatment area:

25% reduction of energy consumption 50% reduction of material consumption 75% less waste and a total reduction on the environmental impact

3 . 4 .1 F u t u r e p r o c e ss m a t e r i a l f o r t h e n e x t g e n e r a t i o n s u r f a ce t r e a t m e n t

o f v e h i c le s w i t h n e w c o m b i n e d m a t e r i a l

Attributes: Environment, Energy, Cost reduction.

Description: Todays technique, zinc phosphate and electro dip coat was developedwhen mild steel and zinc plate steel was used. Zinc phosphate is expensive to monitorand generates large amounts of waste, especially from aluminium surfaces. Analternative is required as its more common that the substrates used on the vehicles aredifferent material such as steel, zinc, aluminium and magnesium, as well as plasticmaterial. High-tensile steel is already in use and stainless material will be implemented.

There is a need to establish an alternative to the zinc phosphate and electro dip coatingwe use in the Swedish vehicle industry, including the Swedish sub suppliers. Methods to

coat polymer substrates should also be investigated. These alternatives shall meet newrequirements on the product and new material combinations and give better resultsregarding energy, environment and resource utilization.

Measurable goals / Expected Results:



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y y

3 . 4 .2 P r o c e ss e n h a n c e m e n t s f o r r e d u c e d e n v i r o n m e n t a l im p a c t

Attributes: Environment, Energy, Cost reduction

Description: Todays paint shop is the single largest consumer of energy, water andchemicals and produces by far the highest amount of waste within the vehiclemanufacturing plant. It is also responsible for a significant amount of emissions to waterand air from the factory. Approximately 80% of the water and 40% of energyconsumption at the vehicle manufacturer comes from the paint shop. The biggest energyconsumption in the paint shop comes from ovens. Air ventilation and heating processbaths come in second place. The energy consumption from combustion of solvents from

the air can vary a lot due to the technology used. More than 2/3 of the waterconsumption comes from the pre-treatment process.

Virtual tools and new materials are enablers to begin analyzing the process in anapproach which can optimize process concepts which have not been possible previously.

The research area will include Ventilation air management including recirculation, cascading, heat exchanging. Low energy and water consuming pre-treatment processes (project area 4.4.1).

Oven designs and energy efficient heating technology (IR, UV and NIR heating). Solvent free paints to eliminate the need for solvent combustion.


The paint shop at the vehicle manufacturers will be able to reduce the energyconsumption by 50%

Water consumption will be reduced to zero Swedish sub suppliers shall be able to meet the environmental and energy demands

set by the automotive industry

3 . 4 . 3 T h e V i r t u a l P a in t Sh o p

Attributes: Quality, Capacity, Cost reduction, Flexibility,

Description:The paint shop is a very large investment and therefore it is essential to

maximize its utilization during its full lifetime, which typically covers multiple generationsof products. Upon product or material changes, a full validation of a complete body-in-white, BIW, is necessary sometimes first at the paint supplier (such as DuPont,Germany) although always within ones own production line. Today quality control (finish,film thickness, and defects) is done manually on only few items and the results arecoming with slow response.


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3.5 Assembly

This area is dependent upon the following technology areas: In-factory logistics and material handling Automation: as robot costs continue to decline and performance increase, the

benefits in flexibility a robot offers compared to e.g. dedicated marriage equipmentbegins to be realistic

Material Technology: new light weight material combinations as well as varying levelsof automation put new requirements on all aspects of production, such as how todesign, build, and assemble joint.

Human / Machine Interface: in order to get the benefits of automation the operatorneeds to come in every increasing contact with robotic equipment. Furthermore, thevolumes of electric data must be synthesized and presented to the operator in such away to not confuse the operator with multiple variants

Visualization: As product development times reduce and hardware prototypes areeliminated, visualization techniques are required for simulating everything from thefactory resources, production process and flow, and the human operations

Software downloads / validation: product differentiation is moving from hardwarebased to software functionality based

Geometry/Quality: virtual pre-matching, improved measurement methods, in-linemeasurements

Alternative Propulsion Systems: in the near future a single assembly line will have tobe able to manage a gasoline, diesel, hybrid, fuel cell propulsion system

Industrial IT: machine control system development Standardization of work process: Increase productivity, quality and cost (safety)

Targets for the proposed R&D areas described below:

Fulfillment of the product demands and specifications. Ability to handle new material in fastenings and joints. Production of different variants on common line for different types of power trains

(conventional and different grades of hybrids) in the same manufacturing system. 30% productivity increase in the production processes. 40% productivity increase in the product development process (Manufacturing

Engineering being a part of this process) with special focus on Manufacturing

Engineering. 30% lead time reduction. 20% lower investment costs. To describe how sustainable assembly shop should look like in 2020. This assembly

shop should be capable ofo producing innovative products.



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systems which require a complete re-thinking of how to assemble these types of vehiclesand then how to do so within the existing production systems.

Product hardware differentiation has been moving towards optimized modularization.Our current production processes are not necessarily synchronized / optimized to howthese product module interfaces are defined. However, there is an even greater hiddenissue within the movement towards product differentiation via software functionality.Whether the delivery module shall have the exact product variant software delivered tothe factory or whether the product variant software shall be downloaded at the OEMfactory is an ever expanding area for R&D and standardization.

Measurable goals / Wanted effects: New assembly techniques; bonding, adhesive tape, clips, click- joint etc. which

support the introduction of new materials and combinations. Production layout / system which in an optimized manner supports the increased

utilization of common base structures in product families. Quick and cost efficient change-over in manufacturing for production of multiple

variants and alternative propulsion systems. Standardized methodology for downloading of software in support of product

variation. Recognition that manufacturing process development is not a roadblock to

implementation of innovative product concepts.

3 . 5 .2 P r o ce s s d e v e lo p m e n t / a u t o m a t i o n

Attributes: Quality, Capacity, Cost reduction, Flexibility

Description: There is a continuous improvement of the existing manufacturingprocesses which can generate records of invention and singular ideas which any programneeds to be open for and encourage. This is especially true for small and medium sizedcompanies.For larger companies, the issue is more a question of how to further optimize onesproduction with automation. With the falling prices and improved performance of robotsa whole new field of flexible automation application has opened up. One can imaginerobots rather than dedicated hardware marrying the BIW and chassis, automated guidedcarts loading and unloading parts on standard pallets or automated recognition of a

specific alternative propulsion system, or equipment automatically sensing the variantand choosing the correct fuel to be delivered to just that vehicle. There also exists theentire field of variant recognition, and process steering control systems which, given thecurrent IT development, should be able to deliver wireless technologies and programsdeveloped in such a way as to be easily reprogrammed based on which modularcomponents or operations are needed. This then opens up the possibility for remote

f f



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3 . 5 . 3 Pe o p l e in p r o d u c t i o n

Attributes: Safety, Ergonomics, Quality, Flexibility, Cost

Description: There are essentially three areas of interest within this research area: howthe operator interacts with the information regarding a given operation; how the operatorperforms the operation and the physical impact upon the individual operator; and finallyhow people interact with equipment and automation within the plant.

The information available for operators in a production system is in one way or anotherconnected to the actions anticipated from the operators. Some of the information isdirectly connected to which operations they shall perform and how these shall beexecuted. Other parts of the information is of a more general type and forms the basisfor correct handling of deviations, but also gives guidance for continuous improvementwork. As the industry moves into the age of visualization, we need to develop smartmethods of presenting the information to the operators without overflooding them.Furthermore, the mass of digital information can also be channeled to new methods forpredicting failure or need for maintenance.

Sweden is and has been a global leader in the area of ergonomics in production. Thisarea needs to be maintained and strengthened both by supporting in-country R&D butalso by collaborating with other global centers of competence in this area. It should benoted that there is a natural synergy with the efforts of visualization in general assemblyas described in section 2.2.4.4.

As presented in section 2.2.4.2 there is a move towards increased automation in thegeneral assembly. The future will present situations where the man / machine interface

will not be stationary but interactive. This is a completely dynamic environment openingup which requires basic R&D in the areas of safety, control, sensors, materialpresentation and handling, man-machine communication, and much more.


Innovative methods to synthesize the masses of data and information and presentonly that data the operator needs to assemble the specific variant in a cost effective,qualitative manner.

The continued global leadership of Swedish Industry and Academia in the area ofproduction ergonomics.

New technology which enables a seamless interaction of human machine /automation in production.

3 5 4 V i su a l i z a t i o n



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assessing the ergonomic impact and cycle time. This is why there is a complete separatecluster focused on the more specific issues.


Ability to plan, optimize, and validate all manufacturing operations without the needfor physical hardware.

Innovative methods to store, validate, update, and maintain visualization data. Fast, efficient simulation of the human operator movements and measurement of

specific parameters based on these movements. New technology which enables a seamless interaction of human machine /

automation in production.

3.6 Geometry and Quality

This area is dependent upon following technology/competence areas: Materials technology in order to understand material behavior Design Product demands Forming technology (geometrical outcome from new and present formingmethods) Assembly technology (geometrical outcome from new and present assembly

methods) Paint process (thermal effects) ? Virtual Manufacturing Engineering Equipment and Cubing technology for verifying processes and products Measuring technology and metrology both for processes and product analysis and

verification. This applies to both in-line and off-line measurements.

Targets for the proposed R&D areas described below: Definition of required geometrical product demands which generates decreased

process problems and increased robustness Product design, which is robust and where ingoing parts are assembled to a final

product, which fulfill desired geometrical demands. Ability to support product/process development with judgment of the geometrical

consequences for new materials/products/processes

Implement efficient tools for the geometry assurance process Supply the product/process with suitable verification technique 20% increased capability 30% shorter lead-time 10% increased robustness 20% increased cost efficiency and reduced ramp-up



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processes to produce less scrap and hereby consumes less energy, material etc which isenvironmental beneficial. This process should be optimized in parallel with demandsetting.

Measurable goals / Expected Results: 20% increased capability 30% shorter lead-time

3 . 6 .2 M e t h o d s o f w o r k i n g f o r a g e o m e t r y a s su r e d p r o c e s s

Attributes: Quality, Lead time efficient, Cost efficient, Robust, Environment

Description: Efficient methods of working are vital for both the product and the processregarding geometry assurance in all phases from design to manufacturing. By developingefficient methods e.g. virtual tools and engineering process, it is possible to already inthe project phase develop a robust product and to shorten the lead time forimplementing new products into production. By this, it is possible to develop/chooserobust processes which deliver products which fulfill required quality demands andhereby produce a minimum of scrap. It is also possible to foresee the effect of new

material/process choices and by this verify the introduction in new projects. By theintroduction of new materials, weight can be saved and herby also the environmental arebeneficial.In order to increase the robustness, it is also necessary to develop efficient tools forfeedback of results through the process chain. Then adjustment of the processes can bedone much faster with the consequence of increased quality and less scrap.


20% increased capability 30% shorter lead-time 10% increased robustness

3 . 6 . 3 Co s t m o d e l s f o r q u a l i t y d e f i c i e n c ie s

Attributes: Quality, Cost efficient, Robust, Change-over efficient

Description: Development of cost models for ingoing processes and product outcome willimprove the possibilities to take the correct actions for improving processes andproducts. Hereby the most cost effective solutions can be chosen in order to eliminatequality deficiencies. Furthermore, it will be a driver for cost effective processes andreactions on process/product variations which will be beneficial for the marketcompetiveness



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energy consumption of the ingoing processes is reduced to meet the need for lessproduction volumes when the amount of scrap decreases which all is environmentalbeneficial. With improved verification techniques, the quality of both the product and the

product performance will increase due to improved possibilities to identify deficiencies inboth process and product.

Measurable goals / Expected Results: 20% increased capability 30% shorter lead-time 10% increased robustness

3.7 Automation of production systems, robotics and controlsystems

This area is dependent upon the following areas: Product design and variant explosion Equipment technology Material technology Joining technology Logistic technology Virtual Manufacturing Engineering Work organization & competence

3 . 7 . 1 Ef f i ci e n t u s e o f e n e r g y a n d m e d i a in p r o d u c t i o n s y s t e m s

Attributes: Environmental, Healthy, Cost efficient, Robust

Description:Tools and methods for estimation of the total energy consumption of a completeproduction system are missing today. To be able to calculate the most optimal use ofenergy, new tools and methods must be developed. The optimization process shouldinclude consumption of media, e.g. water and air. Added material or consumed materialused in the joining process should also be considered. It is, furthermore, required that

the production system can be shut down and started up without problems.Measurable goals / Expected Results:When the energy and media consumption can be estimated in the production process, itwill give the possibilities to minimize the environment impact and reduce cost. Minimizingthe media consumption will also have positive impact on health.A th t b l d d t t d i t ll d ill l dd t th



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over efficient, Capable/Quality, Lead time efficient, Cost efficient/Productive,Robust/Reliable

Description:To be able to deal with the expected increased mixture of different models and power-trains, the automated systems must become less rigid. New product technology will alsoput requirement on materials handling, fixturing and joining methods. Further, theincreased demand of a short time to market calls for equipment that can be reconfigured.A sustainable way to solve this is to increase the reusability of the systems by makingthem more modular and increase their ability to adapt to changes. This calls for bothresearch and development of how to configure modular systems as well as of how to usethe emerging technologies, e.g. driven by new product and material technologies. Thisapproach will support the ongoing transformation into lean manufacturing by addingsimplicity to the change process thus giving production personnel improved tools to applycontinuous improvement also to automated systems.

Measurable goals / Expected Results:In spite of increasing variants and complexities, new solutions will help to keep andimprove productivity in a cost efficient way. A lean approach will shorten lead time andthe reusability will decrease the environmental impact during the coming years extensive

change over.

The impact on the Manufacturing Engineering and Production related targets are: Productivity in Manufacturing Engineering - Medium Productivity increase in the production processes - High Lower environmental impact in the manufacturing processes High

3 . 7 . 3 Sh o r t e r l e a d t i m e s f o r d e v e l o pm e n t , in s t a l l a t i o n a n d s t a r t - u p o f

a u t o m a t i c p r o d u c t i o n sy s t e m s

Attributes: Environmental, Flexible (variant, volume), Change-over efficient,Lead time efficient, Cost efficient, Productive, Robust/Reliable

Description:Research must be carried out on definition and development of modularized systems thatcan easily be implemented into production systems with short lead time. Simulation tools

and models must also be developed to be able to produce completely designed,simulated, verified and programmed production cells (i.e. with both hardware andsoftware). These are key conditions for short installation time and quick ramp-up ofproduction system.




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3 . 7 .4 I n t e l l i g e n t a u t o m a t i o n s y st e m s

Attributes: Innovative, Safe, Motivating, Change-over efficient-ramp-up, Leadtime efficient, Productive efficient, Robust

Description:Development of automatic self-analysis of both mechanical and electrical components,adaptive control of robot systems etc. are required for surveillance and control of theprocesses as well as controlling the status of the equipment. HMIs (Human-Machine-Interface) need to be developed further to enable inexperienced operators to handlecomplex systems without risks and negative influence on the product quality. The plant

control systems and functions for analysis and decision-making on high level are includedin this area.Feed back of parameters from the production process for further analysis and verificationin a virtual environment.Systems that can handle and in an efficient way make use of error and fault status feed-back must also be developed.

Measurable goals / Expected Results:The development of information feed-back, improved HMI and efficient use of error feed-

back will have a significant impact on safety/motivating since better decisions will bemade and risk of errors, both automatic and manual, will be reduced. This will alsoimprove the change-over efficiency, ramp-up and lead time. It will keep up theproductivity by reducing number of errors and improve solution time. The systems willbecome more robust.These systems will be highly innovative.

The impact on the Manufacturing Engineering and Production related targets are:

Productivity in Manufacturing Engineering Medium Productivity increase in the production processes - High Lower environmental impact in the manufacturing processes Medium

3 . 7 . 5 M e t h o d s f o r l i f e cy c l e an d d u r a b i l i t y s t u d i e s

Attributes: Cost efficient, environment

Description:Methods must be developed and used to increase the durability, reusability andsustainability of the production equipment and production systems. This will also createthe prerequisites to make the systems more robust and increase the flexibility (bothinternal production control and resource utilization and external product variants andvolumes flexibility)



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3.8 Logistics & Material Handling/Planning

Logistics and materials handling is an integrated part of the production system. The masscustomized production concept, demanding an huge number and variety of componentsbeing supplied and exposed in production without violating, for example, cost efficiency,component availability and quality, and space, underpins the importance of the area.Manufacturing planning and control is a part of logistics and rules much of theprerequisites for both customer orientation (service level and flexibility) and the internalefficiency of the production operations. Logistics and Materials handling covers parts of,or has important relations to the following areas:

Layout and work station design Facilities and space management Ergonomics Production Management and Manufacturing strategy Work organization, competence and learning Supplier structure, production location and production network Performance measurement Product design, design for logistics and variant explosion Transportation issues in the supply chain

The area is divided into three sub areas, each having research needs to be addressed: Materials supply systems Materials handling operations Manufacturing planning and control

3 . 8 . 1 M a t e r i a l s su p p l y s y s t e m s

Attributes: Cost, flexibility, environmental performance, change-over efficiency,lead time

Description and backgroundMaterials supply systems includes aspects of the supply systems from the materials pointof use in production, e.g. the assembly station, backwards through the production plantmaterials flow and the supply chain, focusing the efficient processing of materials andrelated information.

The production situation for the Swedish automotive industry has changed during the lastdecades. For example the number of product platforms, which are assembled on thesame assembly line, has increased. Further, large demand variations and a stream ofengineering changes have become normal, requiring high flexibility. This is one of themotives for research in the area of materials supply and feeding methods since the



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materials feeding method to use is Minomi (handling and presenting material withoutpackaging), which has the potential of reducing materials handling time, reducing space,and increasing efficiency, but the knowledge of the concept and its potential applications

is limited within Swedish industry. Further, Minomi solutions are in many casescombined with the technique of AGC, Automated Guided Carts.

The design of the supply chains are an integrated part of the production system design,for two obvious reasons. First, the location of a certain production or materials handlingactivity is not fixed, but can be located in the own production plant, at suppliers or atthird parties. The consequences of such decisions, in terms of production, logistics andenvironmental performance need to be further studied. Cross-docking systems have beenused for quite some time to support modern production methods, facilitating leveling and

just-in-time. The effective use of such supply chain methods needs to be furtherevaluated.

In the automotive industry, there is an increased demand for supply chain cost reduction,in areas such as transport, administration, and inventory. At the same time, productionwill become even more customer order driven meaning that high materials flexibility isrequired and materials availability must be secured. Efficient assemble-to-orderstrategies and short lead-time to customers require fast, flexible and reliable supply

chains. Modern Supply Chain Management (SCM) concepts address important causes tocurrent limitations and are attempting to overcome the local company-centric view. Thelean principles to deliver the daily requirement of every part every day might not beapplicable and economically justifiable for OEMs in Sweden, with a supplier structurethat tends to move to the east.

The knowledge of alternative materials feeding methods in Swedish automotive industryis limited and the business case calculation for choosing materials feeding methodsmakes it difficult to recommend alternative methods. The question is, if the business case

calculations for choosing materials feeding methods used in Swedish production systemshave the right assumptions and take all important considerations into account?

Measurable goals / Wanted effects: Reduction of materials handling cost A black-box-system that communicates with several facility systems Specified design parameters that should be considered in varying part/facility

characteristics.

A methodology to evaluate, compare, design and estimate costs of materialsfeeding methods Estimate the efficiency and effectiveness of cross docking operations Increase the knowledge of how different production contexts affect the choice of

materials feeding method, while also implying suitable combinations of differentmaterials feeding methods



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Description

Modern manufacturing processes and supply chains design require materials handlingoperations that are robust and reliable in relation to the supply chain, maintain thequality of the parts handled, and are efficient from a man hour and cost perspective. Ifthe operations are not fulfilling such demands, the design options of the production workstation and the supply chain are restricted which will lead to lower performance of thewhole system.

Materials handling has not been in focus in research for many years, except for somespecific areas among which can be mentioned design and control of automatedwarehouses, work cell control of robot handling systems, and traffic control systems of

automated guided vehicles. What is perceived important is the addition of research thatfocuses typical materials handling operations of the supply chains described above.Related to the principle materials feeding principles mentioned, e.g. kitting and minomi,there is a need of developing the materials handling activities involved at a more detailedlevel. The previous research area answers the questions of when and why using theminomi, etc, while this research area answers the question How to perform thehandling activities involved. This involves several aspects, e.g. equipment, informationtransfer, work station design, and operations control. The effective and efficient designsof the following activities are examples in need of further research:

Design of kitting operations Design of repacking and packaging downsizing operations Design of transport and transfer equipment for work station feeding Design of minomi devices

Packaging systems is a vital part of the supply chain and production system. Thepackaging serves several purposes and functions of great importance for the efficiency,flexibility and environmental performance of the production system. The flow of

packaging consumes resources in the production plant both when filled and empty. Thevalue of presenting materials in an effective way to assemblers and mechanical devicesare very high, but this has to be combined with a packaging system that is efficientthroughout the supply chain and in the internal plant operations. Another importantaspect is the function of the packaging to carry and display information. As for othersupply chain issues, the location of suppliers in relation to the Swedish production plantsis a complication. Packaging issues is an integrated part of the problems stated above,and in the previous section, but is worth put forward separately in the text. Research hasto address the work station and plant efficiency, given the settings of a dispersed

supplier structure and low volumes of individual parts, among other things characterizingthe Swedish automotive sector, aiming at developing and guiding the choice of effectivepackaging and packaging systems.

3 8 3 M a n u f a c t u r i n g p l a n n i n g a n d c o n t r o l



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control strategies is of great importance, e.g. different demand, product and materialflow characteristics, in order to design a planning and control system that matches theproduction situation. The same is true for the interplay with the design of products, and

production and materials handling systems.

An important aspect is the planning information and its quality in planning and controlprocesses. This involves information from actors in production, in other functions of thecompany, and from external parts. The lean philosophy and the demand for highavailability of production resources highlight the interplay between the productionsystems, the materials handling system and the shop floor control. The application ofpull-based control in environments no having simple and typical characteristics for suchsystems are important to study.

The specialization and globalization trends makes it important to address issues relatingto the planning and control of production networks and entire supply chain planningmethodologies, partly by employing new advanced formation and planning systems. In alean production context, manufacturing and supply chain planning should focus ondesigning and aligning pull systems with material supply, materials handling, packagingand production systems.

Planning and control in production networks and supply chains have to enable planningsystem support for creating planning visibility for supply chain design, coordinatedplanning in production networks, and event-based control in order to better adapt toflexibility demands. Planning and control systems for mass customized products atmixed-model assembly lines require, on one hand, order schedule stability in terms ofe.g. long order time fences. On the other hand, one would like high flexibility toaccommodate disturbances in supply and production, and the ability to respond tocustomer demands. This calls for a planning system not only being able to produce longterm stable plans, but also being able to re-plan at shorter notice by means of

reconfiguration resources. For the second purpose, supply chain monitoring systems areprobably required in order to identify possible disturbances, but these have to becombined with decision systems that allow proper actions to

sustainable manufacturing systems rd program third edition jan 2010

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