1Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Migration Manufacturing©
A New Approach for Automotive Factory Planning
Dr.-Ing. M.S.M. Thomas P. MeichsnerExecutive Director
Production Technology, Press Shops, Specialty CarsWilhelm Karmann GmbH, Osnabrück
2Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Karmann –more than 3,3 million cars produced since 1949
3Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Global Locations
AGS GmbH,OsnabrückLogistic Services
Karmann U.S.A., Inc.Plymouth, MichiganTechnical DevelopmentPrototypesRoof Systems
Karmann-Ghia do BrasilSão Bernardo do CampoProduction TechnologyStampingVehicle Manufacturing
Karmann-Ghia de Mexico, PueblaRoof System Production
Karmann-Ghia de Portugal Vendas NovasSeat Cover Production
Karmann SunderlandU.K.Roof System Production
Karmann JapanYokohamaSalesEngineering
AKC Componentes automotivosResendeProduction Technology
Karmann ZaryPolenRoof System Production
Karmann ChorzówPolenTooling
Wilhelm Karmann GermanyHeadquarters: OsnabrückVehicle Engineering, Production Technology,Roof Systems, Vehicle Production
Karmann Engineering Services GmbH,BissendorfEngineering
4Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Powertrain & Chassis Integration
PrototypesVehicleTesting
Engineering/Concept
MachiningTools & DiesBIW AssemblySystems
QA Tooling Stamping Paint Shop Final Assembly
Module Manufacturing
Body-in-White
Styling Concepts/Advanced
Engineering
Package/MeasureConcept/
Surface Class A
Design/ Engineering
PlasticsTechnology
RoofSystems
FEM Analysis
Soft-topProduction
Full Service Supplier
5Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Selected Reference Projects…
A6 Scania
Audi Cabrio A3 Sportback Vaneo
Megane
SLK
MAN
Sprinter Bentley
Crossfire
CLK
6Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.051SW
Limousine
Station Wagon
Flow Tail
Off-Road
Coupé
Cabrio/Roadster
70er
Limousine
Coupé
Cabrio/Roadster
60er
Off-Road
MPV
Limousine
Station Wagon
Flow Tail
Coupé
Cabrio/Roadster
80er
MPV
SUV
Compact-MPV
Off-Road
Limousine
Station Wagon
Flow Tail
Coupé
Cabrio/Roadster
90er
MPV
SUV
Compact-MPV
Off-Road
Limousine
Station Wagon
Flow Tail
Coupé
Cabrio/Roadster
Cabrio Coupé
Coupé-Limousine
Tall Wagon
2005 - 2010
Sports Tourer
SAV
…
Market Development Niche Vehicles
[Polk Studie 2006]
7Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.065SW
Market Development –Example Compact SUV
1999 2001 2002 2003 2004 2005 2006 2000
5000
10.000
15.000
20.000
0
21.00019.800
19.000
15.500
9300
14.500
10.500
85008000770075006500
MercedesML
ToyotaRAV 4
HondaCR-V
NissanX-Trail
BMWX5
BMWX3
VWTouareg
HyundaiTucsow
HyundaiSanta Fe
AudiQ7
[Units/year]
year
[Autobild]
8Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.053SW
Platform
Platform Strategy
9Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.105SW
Roof Frame
Roof
III. Body-in-WhiteFrame
Rear section
Main Floor
Front Section
Floor
Production Steps
I. Underfloor
Basis: Limousine
Example: Cabrio Variant
Side Panel
Side Panel
II. Underfloor withSide Panels
Closures
Doors
Fender
Hood
IV. Body-in-White
Assembly Sequence Body-in-White Platform Strategy
10Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.066SW
Component
Productlevel
Station System
Product
Part
Feature
Section Plant Network
Portfolio
Productionlevel
Agility
Changeability
Flexibility
Reconfiguration
Umrüstbar-keit
Re-tooling
Changeability Typs of Production Plants
11Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.067SW
Productlevel
Station System
Assemblies
Underfloorgroups
Plant
Body-in-White
Productionlevel
Body-in-White
Assembly
Komponenten
Floor Assembly Roof Hatches
•• • •• •
Robots, Welding guns,Tension sequences•• •
Levels of the Body-in-White
12Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.054SW
SOP: Start of Production; EOP: End of Production
SOP EOP
Units
Start EndProduction
Svolatil
Sspread
Start-upangle
Ω
α
Speak
Slevel
SAverage
SEnd
Reference Life-Cycle Curve and Requirements of amigrating Body Shop
Requirements
•Reduction of
investment >30%
•Multi-Model-Ability
min. 3 models
•Scalability ± 30%
•Smooth integration
of new models
•High degree of
re-integration
•Quick return of
capital
Reference Curve Volume Development
Time
End ofproduction angle
13Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.070ASW
Modularity
Changeability Typs
Compati-bility
Mobility
Universality
AB
C
Scalability
Typ
Variant
Flexibility Typs
Re-Integration
Process
Volume
Part
MigrationPrinciple
Multi-Model andScalable
Production Volume
FlexibleFramingStation
GeoHandling •• •
Requirements and Targets for theMigration Concept in the Body-in-White Production
14Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Flexibility through Movability
[BMW]
15Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Re-Use of Production Equipment
Plant and Equipment Layouts
A209
The re-use of production equipment is in principle possible. However change-over strategies and adaptation is difficult and often not possible. After end of production (EOP) the integration of a new model is possible.
Therefore EOP and SOP are directly related to each other.
EOP 12/07
EOP 09/09
16Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Production LayoutBody-in-White Production (Example)
[BMW]
17Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Framing Station
An expansion of the line ist hardly possible.
18Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.094SW
Characteristic• Stable sales•Low flexibility• No variants
Focus: Line tact
Example•E-Class (old)
Solitude Principle
Production for oneBody-In-White-Model
Volume
Time
Vmax
Start Productionphase
End
Migration Principle
Production for many Modelswith additional Variants each
Characteristic• Life Style Sales•Different B-I-W/
Models•No common platform•Production equipment canfollow demand on short termin
Focus: Moveable, scalablework contents
Example•Karmann
ModelsV1
V2
V3 A
B
C
Volume
Time
Flexible Principle
Production for many Body-in-White Variants of on Model
Characteristic• Dynamic sales•Compensation of volumeChanges through additionalB-I-W Variants
•Flexibitlity only with sameplatform
Focus: Line balancing
Example•Audi A3
Coupé
Limousine
Station WagonCabrio
S S S EndStart
Volume
Time
VmaxVariants
Manufacturing Principles of the Body-in-White Production
19Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.059ASW
Principle
Structure
Sub-Systems
Specific ChangeabilityEnablers
Special FlexiblityTypes
Migration Concept
Structure of the Migration Concept
20Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.205SW
Technology ControlInfrastructure
Human Resources
Sturcture of the Concept
Types of Flexibility
Logistic
Scalability CompatabilityModularityMobilityUniversality
Versatile
Product Mix Successor Volume Space
Solutions for the Concept Structure
21Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.118SW
Tg : Type-related
Tu : Type-unrelated
Jigs and Fixtures
(Tg)Rotary Fixture
(Tu)
Welding Gun (Tu)
Robot
Turn Table
Storage
Safety Fance and Equipment (Tu)
ControlerNetwork (Tu)
(Tg)(Tu)
(Tu)
(Tu)
(Tu)
Type-Related and Type-Unrelated Componentsand Sub-Systems
22Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.078SW
M
Geometry Welding Special Tasks
Content:• Jigs and Fixtures• Robots• Gripper Technology• Welding Gunswith/without changing
•Robots•Welding Gunswith/without changing
•Measurement Technology•Touch and Pierce•Assembly Technology•Laser Technology
Invest-relation:
100%(Basis)
20% up to 200%
Types of Production Cells
23Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.097SW
HandlingLocation and
Clamp SystemsJoining Technology Forming and
ProcessingTransport andBuffer Sytems
ControlSystems
PeripheralSystems
Examples•Grippers- Geometrical
gripper- Multi-functional
gripper- Sorting gripper- Modular gripper
•Robot used asa manipulator
- stationary- mobile
Type-Specifitylow
Re-usablitygood
•Clamp systems(LCS)
- flexible LCS- adaptive LCS- modular LCS- dynamic LCS
high
middle
•Welding- Spot welding- MIG welding- MAG welding- WIG welding• Laser welding• Riveting• Bolting• Adhesive
low - middle
good
•Soft touch formand pierce
•Hemming- Roller hemming-Table top
hemmer•Milling•Drilling•Piercing•Parting
high
middle
•Portal systems•Mobile Systems•Conveyor systems•Stationary buffers•Combined
Buffer / Conveyorsystems
•Loading stationfor material
• Unloading station- manual- automatic
low
middle
•Networks- LAN- WAN•Control•Regulate•Measure
middle
good
•Safety and protectivesystems
•Media•Identification
systems (RFID)
low
good
Body in White System Components (Examples)
24Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.116SW
Robot
Hemmingfixture
Layout 1
Doorfront/left
Doorfront/right
Doorrear/right
Doorrear/left
Door front/right
Door rear/right
Layout 2
Door front/left
Door rear/left
Capacity Increase of Roller Hemming Cell (Example)
25Migration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
14.088SW
AlternativesMultiplication Network
BasisChanging element
Structure
Parallel Sequencial
Station
Sub-SystemMultiplication Extension of Motion
ComponentsMagazine Magazine
AB
Sub-ComponentsExchange Adaption
RoutingRepeatition
2xRe-routing
Work Contents
Doublication Separation
Sourcing?
external Internal
Purchase (external) Addition (internal)
A
Technical Changeability Concept of the Core Competenceof the Migration Principle
26Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Reduction of the Production Equipmentfor a Front and Rear Closure
14.227SW
R1
R2
Modular fixtures
R1
R2 Roller hemming bedexchangeable
27Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.226SW
Modular Equipment for the Productionof Front and Rear Closures
28Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.203SW
Direction of the migration
Model A
Phase 1 Phase 2
Model A Model B
Core production line
Growth sectionof the equipment
New coreproduction line
Migration Path from outer to inner
29Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Migration Concept on 3 Levels
14.122SW
Plant level
Line level
Cell level
30Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.112SW
Migration on Plant Level
Plant 1
Capacity
Plant 2
Capacity
100%
body-in-white paint assembly
100%
body-in-white paint assembly
31Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.086SW
a) Layout b) Volume Development
e.g. Wedding-Line
Base
AdiitionalTransport-Systems
Time
Volume
Transport-net
Step 1
Step 2
Step N
Additional Cells
e.g. Geo-Cell
Layout Concept Chess
32Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.084SW
a) Layout b) Volume Development
Base
Step 1
Step 2
Additions toWelding Line
Zeit
Volume
Step 2Welding Line
Welding LineStep 1
Main Geometric Line
Base Line
Layout Concept Meander
Characteristics: tact-free definition, free choice of cells, scalable, defined growth parths
33Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
mögliche Platzierung der Fertigung Boden vst. (Layout lt. Anfrage)
Dach
RespotMAG
Respot
Produktions-
szenario
EHB
Rollenbahn mit Skid
Lift
Geo 2Geo 1
Inline
Respot
Layoutvariante:
§ solitär, Neuanlagen
§ Brownfield, Hallen Shedbau
§ 16,6 EH / h
Mäander Layout –One Car Model
34Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
§ Integration von:
6 Roboter Respot 2, 1 Roboter Taping 21 Roboter Dachstation, div. Stauförderer und Behälter
Produktionsszenario
Dach
MAG
Inline
Respot
Respot
Geo 1 Geo 2
Respot
Layoutvariante:
§ Mix, Integration
§ Brownfield, Hallen Shedbau
§ 16,6 EH / h
Mäander Layout - Two Models
35Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Kommissionierung Spriegel
Kleben Seitenrahmen
Taping
Geo
Aufgabe Boden vst.
Framingstation bis 3 Typen erweiterbar. Zunächst nur Basiseinheit mit kurzer Linearachse, 1 Laufwagen und Zustelleinheit verbaut
Details of the Layout
36Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
2 neue Spannrahmen
1 neue Kleberanlage
1 neue Bauteilablage
5 neue Greifer
2 neue Bauteilbehälter
Framingstation auf 2. Typ erweitert. Verlängerung Linearachse, 1 Laufwagen neu hinzu, 1+1 Spannrahmen hinzu
Details of the Layout with Additional Equipment
37Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Comparison of Space and Investment
Production Space and Investment (direct und normed)
Model A solitary Model A Mäander
Model B solitary Model A and Model B Mäander
4500 m² 100 % Basis Mio. € 4300 m² 102 % Basis Mio. €
4300 m² 41 % Basis Mio. €3100 m² 95% Basis Mio. €
Σ = 7600 m²
38Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.213SW
Volume
Time
Model AModel A + B
Model A + B + C
100
150
50
Units / day
Sce
na
rio
1
Sce
na
rio
2
Sce
na
rio
3
Sce
na
rio
4
0
Assumption:2 shifts/day, each 8 hours
Production Volume Scenarios for 3 Models of different OEMS
39Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Simulation Result
14.234SW
Model A (~60%)
Model B (~30%)
Model C (~10%)
Total performancein average 172 units/day
Share
100
0
[%]
60
40
20
Single valueSliding average
[IPH]
40Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Evaluation of Investments (Price Tree)
14.200SW
S00
S11
S12
Meander
Solitude
Production unit development
Production lines
Model integration
A
B
C
41Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Comparison of Investments of theSolitude and Migration Concept
14.109SW
Solitude concept Meander concept
Investments 13,8
10
5
0
9,3
4,8
[Mio. €]
Mo
del
AM
od
el C
Start scenario
4,22
Sce
na
rio
1
Mo
del
B
5,32
Model A
Sce
na
rio
2
Integration Model B
ProductionSystems
Processtechnology
Robotics
others
Integration Model C
8,12
Sce
na
rio
4
others
ProductionSystemsRobotics
Processtechnology
7,42
Sce
na
rio
3
42Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.114SW
Cash Positive
Cash Negative
Time
Cumulated Cash Flow[Mio. €]
SOP(C)SOP(B)- 4 M
SOP(A)- 6 M
- 10 months
Interesteffect
StartCash FlowModel A
StartCash FlowModel B
Investmentsingle-line Model B
Meanderbase
Expansion of investment forvolume and/or Model B
Base
Interest effect
Cash Flow of a Migration Production StructureCompared to a Solitude Production
43Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner14.100SW
high
medium
low
low medium high
Case B: For increasing volume under-investedhigh variable unit production cost
Volume
Increasing variable Production unit cost
Inestment
Raising fixedproduction cost
Case A: for decreasing volume over-investedhigh fixed unit production cost
Case A
planned volume
planned volume
Case B
new volumeafter appr. 2 years
new volume
Case BMedium production withlower investment, increasingunits produced
Economic Development in Case of Volume Deviation
Case AHigh volume with high investmentin order to minimize unit cost,decreasing units produced
44Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Economic Development of Production Volume Deviations
high
medium
low medium high Volume
Maximum variableproduction cost
Investment
Case A: avoidance of high fixedproduction cost
Case B: avoidance of high variableproduction cost
Increasing volume; under investedhigh variable production cost
Overinvested for low volume,low profitabilityHigh fixed production cost
Maximal fixedproduction cost
Vehicle B
low
Investment step
High volume with migratinginvestment in order to minimizeunit cost
Investment path
De-investmentpath
Optimal migration path
Vehicle A
45Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Production Strategies
Modulare plant Wildemann 1988
Fractale plant Warnecke 1991
Bionic manufacturing Okino 1993
Holonic manufacturing HMS 1994
Network plant Wiendahl 1996
Migration Manufacturing
Strategy Founder Year
46Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Summary
- Life-style effects in the market and technical innovations require continuously
new car models in short sequence and with decreasing product life-cycle.
A high competitive pressure requires low cost and
low budget production concepts.
The Body-in-White production is a key element in the automotive
manufacturing process.
A Body-in-White production based on the new Migration Concept is much more
advanced compared to the existing production concepts in respect of flexibility, economics and investment and market risks.
Migration Manufacturing is a new concept for factory planning. It reflects the idea that plant layouts are a living organism that pro-acts with market and technology changes.
47Wilhelm Karmann GmbHMigration Manufacturing Dr.-Ing. M.S.M. Thomas P. Meichsner
Thank you for your attention!
Publisher: PZH Produktions-technisches Zentrum
ISBN-10: 3939026638
ISBN-13: 978-3939026631
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