Published Article / This paper presents the work on the development of a digital simulation model for the transportation line in a local automotive manufacturing plant. It describes a structured procedure of data collection, digital design, model building, activity creation, and process simulation using simulation tool Delmia. Based on the digital simulation model, new alternative concepts of production line planning strategy can be easily integrated into the model to evaluate the cycle time/cost and to optimise the production line. The demonstration result indicates that digital simulation can be used as a powerful tool to reduce planning risk, identify material flow bottlenecks, and to improve throughput and knowledge share within the company.

Scania är ett av de ledande företagen inom tillverkning och distribution av tunga lastbilar, bussar och motorer för marina och industriella miljöer. Scania arbetar tillsammans med sina kunder för att utveckla kundspecifika lösningar. Det leder till att Scania har väldigt stor variation på sina produkter. Variationen på produkterna kräver ett flexibelt arbetssätt som tillåter förändringar. Det har Scania löst med ett modulärt produktsystem. Det innebär att antalet komponenter begränsas medan kombinationen av dessa genererar ett nästintill obegränsat antal varianter. Eftersom varje lastbil är unik påverkar variationen även produktion. För att säkerställa att en ny lastbil går att tillverka arbetar Scania med digitala provmonteringar. Provmonteringarna genomförs på Scanias avdelning för chassimontering av gruppen MPPAP. Enligt dagens process för digitala provmonteringar bearbetas en lastbil i taget och varje digitalt test består av två delar, Virtual Build (VB) och Digital Test Assembly (DTA). När den digitala provmonteringen går att genomföra utan avvikelser kan lastbilen provmonteras fysiskt i en Physical Test Assembly (PTA). I dagsläget finns ett behov av att effektivisera processen för digitala provmonteringar. Målet är att kunna bearbeta och verifiera monteringen för flera lastbilsmodeller i ett och samma test. I dagsläget går det inte att genomföra dessa tester eftersom detta arbetssätt förutsätter att data kan filtreras i Delmia. Detta examensarbete genomfördes för att undersöka hur filtreringen i Delmia skall genomföras, vilket även omfattade vilka möjligheter, begränsningar samt förutsättningar som finns för implementering av detta arbetssätt. Filtreringsmetoden som togs fram under studien baseras på information och funktioner som idag finns tillgänglig i systemen/programmen som används på Scania. Metoden förutsätter att all inputdata kontinuerligt uppdateras i Enovia (Scanias PDM-system) samt att den finns tillgänglig för provledarna på MPPAP. Metoden kan i dagsläget endast implementeras till viss del, eftersom tillgången till inputdata är begränsad. Utifrån de begränsningar och förutsättningar som finns idag genomfördes ett verifierandetest där tvärbalkarna för tre lastbilsmodeller filtrerades ut i Delmia. Studien påvisar att filtreringen i Delmia går att genomföra med information och funktioner som i dagsläget finns tillgänglig. Dock går det inte att bevisa exakt vilka vinster det nya arbetssättet medför, vinsterna går endast att approximera. Detta på grund av att filtreringsmetoden befinner sig i ett prototypstadie och har därför inte används vid en digital provmontering av en hel lastbil. För att effektivisera dagens arbetssätt gällande digitala provmonteringar på MPPAP måste metoden som togs fram under studien testas och utvärderas i ett mer omfattande test, som påvisar vinsterna enligt de begränsningar som finns idag. Vid full implementering av arbetssättet kommer det att krävas en resurs på P&L som genererar och underhåller den inputdata som krävs. Detta är ett beslut som måste tas av högre chefer, när vinsterna kan bevisas. / Scania is one of the leading companies in manufacturing and distribution of heavy trucks, busses and engines for marine and industrial environments. Scania works together with their customers to develop customized solutions. Which leads to a broad variety on Scania’s products. The variety demands a flexible method to allow change. Scania’s solution to this problem is a modular product system. It means that the number of components are restricted but the combination of these generates an almost infinity number of variants. Since every product is unique, the variety also affects production. Scania works with digital test assemblies to secure the final assembly of a new truck. The MPPAP group at department of chassis assembly does testing to see if the parts fit together. According to today’s digital testing process trucks are tested one by one and each test has two parts, Virtual Build (VB) and Digital Test Assembly (DTA). When the digital assembly testing can be done without deviations, then and only then can the testing in a physical environment start - Physical Test Assembly (PTA). There is a need today to make the digital assembly testing process more efficient. The goal for this type of testing is to be able to test several trucks simultaneous. This method is not possible today due to lack of possibility to filter data in Delmia. This Master Thesis study was done in order to investigate how the filtering method in Delmia could work, including possibilities, limitations and conditions for implementing this way of working. The method developed during the study to filter data is based on information and functions that currently are available in existing systems at Scania. This specific method requires all input data to be continuously updated in Enovia (Scania’s PDM-system) and the test leaders at MPPAP have access to it in real time. The method can only be partially implemented today, due to limited input data. With the current limitations and conditions a test was executed to verify the filtering process of three truck models cross members in Delmia. The study proves that filtering in Delmia is possible with the information and functions that currently are available at Scania. However the advantages with this way of working is not yet proven. They can however be approximated. The reason being it’s still in a prototype stage and has not yet been tested on an entire truck at a digital assembly test. In order to make testing more efficient regarding the digital assembly testing at MPPAP today, the developed method needs to be tested and evaluated at a larger scale to demonstrate the benefits with existing limitations. When this new way of working is going to be implemented there will be a need for recourses at P&L that can generate and maintain the required input data. A decision to secure resource needs can be taken by management when the method is fully verified.

<p>Typically, when Faurecia in Torsås are planning a new assembly line, one of the steps is to build a full-scale model of the line in card board, a form of mock-up planning. Faurecia has shown interest in finding an alternative methodology. The purpose was to explore the possibility of replacing today's cardboard based mock-up planning with models in a digital simulation environment.</p><p>The purpose of the thesis has been to answer some of these complex questions; What are the benefits of using a simulation tool? In what way can we use it? If we choose to use a simulation tool, in what way does it affect our way of planning an assembly line? What are the advantages and disadvantages? Are there any economical and social aspects?</p><p>Our results made us realize that a digital simulation tool does not replace the card board. On the other hand simulation could be used as a complement. Card board exercises and simulations play two different roles in the development of an assembly line. The use of card board is an excellent example of how you can generate a wide range of creative solutions at an early stage of the design process. This offers the possibility to create and evaluate several different concepts during a short period of time.</p><p>We believe that the benefits of a simulation tool come in handy at a later stage of the design process, when a conceptual solution is selected. The simulation tool will be able to evaluate the solution and identify where problems may occur. The output of the simulation tool may also be used as a communication tool, internally as well as externally.</p>

Typically, when Faurecia in Torsås are planning a new assembly line, one of the steps is to build a full-scale model of the line in card board, a form of mock-up planning. Faurecia has shown interest in finding an alternative methodology. The purpose was to explore the possibility of replacing today's cardboard based mock-up planning with models in a digital simulation environment. The purpose of the thesis has been to answer some of these complex questions; What are the benefits of using a simulation tool? In what way can we use it? If we choose to use a simulation tool, in what way does it affect our way of planning an assembly line? What are the advantages and disadvantages? Are there any economical and social aspects? Our results made us realize that a digital simulation tool does not replace the card board. On the other hand simulation could be used as a complement. Card board exercises and simulations play two different roles in the development of an assembly line. The use of card board is an excellent example of how you can generate a wide range of creative solutions at an early stage of the design process. This offers the possibility to create and evaluate several different concepts during a short period of time. We believe that the benefits of a simulation tool come in handy at a later stage of the design process, when a conceptual solution is selected. The simulation tool will be able to evaluate the solution and identify where problems may occur. The output of the simulation tool may also be used as a communication tool, internally as well as externally.

Práce seznamuje s technologií Digitální továrny, analyzuje produkt Delmia. Popisuje implementaci produktu ve společnosti Škoda auto a.s.. V závěru předkládá přínos pro rozhodování managerů a návrhy na změny systému před zavedením v pobočných závodech společnosti.

<p>The objective with this thesis project was to with the simulations software Delmia make a working build philosophy for the new concept of the fixed leading edge for the Airbus A320 airliner, but also to make two conceptual fixtures in the modular framework BoxJoint for pre-drilling of two sub assemblies.</p><p> </p><p>Everything started with a study in Delmia to both recap on previous knowledge and to learn more about it. This was followed by early simulations on the new concepts that were provided by project partners. Then a study was made in the Affordable Reconfigurable tooling, ART-concept. A suggested build philosophy was created and possible areas for automation were identified. These areas were all the drilling and fettling operations except the drilling in the last stage where the pre-drilled holes are opened up. More investigations needs to be done to see if a robot can install and remove slave pins that are used in the last stage. Two conceptual designs on fixtures were created where one uses two industrial robots with vision systems to get the correct accuracy when drilling the product. The other was build to be able to use a Tau-Gantry robot solution together with a vision system.</p>

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The objective with this thesis project was to with the simulations software Delmia make a working build philosophy for the new concept of the fixed leading edge for the Airbus A320 airliner, but also to make two conceptual fixtures in the modular framework BoxJoint for pre-drilling of two sub assemblies.   Everything started with a study in Delmia to both recap on previous knowledge and to learn more about it. This was followed by early simulations on the new concepts that were provided by project partners. Then a study was made in the Affordable Reconfigurable tooling, ART-concept. A suggested build philosophy was created and possible areas for automation were identified. These areas were all the drilling and fettling operations except the drilling in the last stage where the pre-drilled holes are opened up. More investigations needs to be done to see if a robot can install and remove slave pins that are used in the last stage. Two conceptual designs on fixtures were created where one uses two industrial robots with vision systems to get the correct accuracy when drilling the product. The other was build to be able to use a Tau-Gantry robot solution together with a vision system.

Repetitive injuries have been a major obstacle in production assembly lines all over the world. These injuries have greatly reduced the production efficiency of assembly plants and also negatively affected human health. Various attempts have been made by the Canadian government through the Workers Compensation Board (WCB) to prevent the occurrences of these injuries because of the associated cost and effects. These attempts failed as the cost of injuries acquired in the workplace continues to increase. For example, in New Zealand alone, the total cost of accidents in 2005, is estimated at $300 million (Accident Compensation Corporation, 2005). In Canada, the number of accepted claims alone amount to 15623 people (Workers Compensation Board of Canada, 2003).<p>A human body can be viewed as a mechanism that is composed of links and joints controlled by a central nervous system and are subject to stress, strain, fatigue and failure as can be observed on a regular industrial robot. But unlike the robot which is designed proactively, these stress and strain factors could be because of certain conditions such as inappropriate work posture, poor assembly line design, excessive workload, and poor work conditions. <p>Often, it is almost uncertain to make a conceptual assessment of the appropriate ergonomic design of a production system before the assembly line is built and put in use. This research will propose a general computer-based methodology for analysis of work injuries given an assembly line where human workers perform repetitive operations. The general methodology integrates sophisticated computer software systems for biomechanics simulation with various manual measurement techniques and methods. The research further proposed a simple and handy synthesis method with which problematic areas of assembly line design, with special reference to human work design can be identified and improved. The proposed methodology for analysis and synthesis is then implemented in a real assembly line to understand the effects of different work activities on the human body. Various software packages and motion tracking techniques will be considered prior to the actual implementation of the final methodology. A rule of thumb table will also be presented as a guideline for the re-design process. The research also proposed a general procedure and specific formula within a specific regional context to calculate the costs of worker injuries in real-life assembly system. This formula thus allows us to obtain the total cost of injuries in a production assembly line, making it possible to optimize the design and operation of the assembly line.