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Ready4realityVirtual commissioning

at vcc

Andreas Jonsson MSc.Method Lead BIW

Manufacturing EngineeringVolvo Car Group

Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

2Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

CHINACar & Engine ProductionProduct Development

BELGIUMGentCar production

USACamarilloDesign centre

SWEDENGothenburgHead officeProduct development,Car production

Skövde, Floby and OlofströmComponent manufacturing

MALAYSIAKuala LumpurAssembly factory

SPAINBarcelonaDesign centre

DENMARKCopenhagenRD Centre

Volvo Car Group$9B

USACharlestonManufacturing Plant

3Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Our journey forward

4Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Moremodels!

Rapidfollower!Designed

around you Truly

global

5Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Moremodels!

Rapidfollower!

But how?

When your are small…

Designed around

you Truly global

6Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

>80M

0,5M

7Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

ShortenLeadtime

(40 to 30 Mts)

FlexiblePlants

Decisions solely on Virtual Data

Fast and nimble

Reduce physical

prototypes

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Virtual trust enable more, earlier descisions with high quality

Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

High detailed models

High Quality PLM data

Complete simulation models(Incl. Signals & behaviour models for all equipment etc.)

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Current capabilities

Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

30+ engineers within process simulationExtensive standards & specifications (Sim, Robot, Plc)VOLP – Volvo OffLine Programming tool

Not utilizing the full potential…

10Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Ready 4 reality achieve higher maturity level much earlier

Use what we already

have

Add the real control system and

Code

Virtual Commissioning captures the whole station logic!

fully verified process without

physical installation

11Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

PS PC FDJ TT J1

Core phase

Virtual commissioning

Develop Process/product PLC, installation and

commissioningInstallation and commissioning

Develop Process/product and

PLC

development logic much higher virtual focus

Invest more time here… … to gain time here

Complete virtual installationDevelop More robust processesVerification without physical prototypesDebug process logic off-line

12Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Implementation step by step

2013 2014 2015

Decision to include VC in car projects

Decision to investigate VC

Initial WS at Siemens

Scope for Pilot

decided

Second WS at Siemens

Pilot report out

Working methods

Internal VCC Pilot

13Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Vitual Commissioning pilot scope & findingsscope: Small ”simple” station Evaluate Siemens technical solution Start develop methods and workflows Suggest next steps

tech: ABB IRC5 Spot-servo and Handling/Glue Siemens CPU 319F Process Simulate & TiaPortal Simatic Net OPC Server

Findings: No adaptions needed for PLC or Robotics Very powerful debugging Easy, fast setup

Must C the need for: Commonality -> support auto generation Co-locate -> create understanding Co-operation -> responsibility split (VCC/Linebuilder)

14Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Virtcom research project

15Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

virtcom work packages

16Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Current activities new car projectscope: 2 stations for 2 model introductions Process Simulate connected via OPC or Simba Reviews during project to track progress VC presented before installation activities start Safety NOT a demand

Modified hand-over to supplier: Event based simulation instead of Gantt Charts Equipment with behavior models instead of simple

kinematics Think about and prepare for VC, reusable logics

Take more responsibility!

Measure success rate: Process related errors during commissioning Over all commissioning time of station Did we miss something? Preparation in early phases (more/less)

17Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

other activities input generation

scope: Focus on the input to Virtual Commissioning How much can we auto-generate?

POC study:Project together with EPLANUse information from process planning software to generate: Electrical schematics I/O lists

Start with respot stations in Q3 2015

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19Date Created: July 9, 2014Ready4Reality Virtual Commissioning at Volvo Cars, Andreas Jonsson, Volvo Car Group

Thank you!