Digital Transformation for one of the world’s leading electric car manufacturer

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  • Client was looking for optimising Body and Weld shop process
  • Synchronise the jobs at subcomponent work centres producing parts in the exact sequence as the mainline
  • Body and Weld process need to be as per the vehicle body specifications and each vehicle needed to receive predefined Weld process depending upon the component model

Project Scope:

  • Create a system that provides synchronisation capabilities between subcomponent work centre and mainline
  • Define the sequencing and queue process to ensure subcomponent and vehicle body station matches on mainline
  • Implement component and vehicle tracking system that ensures specific vehicle body receives predefined weld process to attach the subcomponents
Project scope

Solution Approach:

  • ATS created a Vehicle Broadcast System (VBS), using Inductive Automation’s Ignition product, capable of receiving the vehicle body specification broadcast from their Manufacturing Execution Systems (MES) system
  • Broadcasted data is used to communicate the body specification option codes to the offline work cell operators, PLC, and robots thus insuring the offline production is in sequence to the main line
  • VBS provides the build queue and RFID management for the main line.  Body Sequence Numbers (BSN) is written to carrier mounted RF tags
  • The solution displays the option content at each Body and Weld subcomponent work centre in the sequence for which the vehicles are to be produced on the main line
  • It provides the subcomponent weld robots with the correct program number ensuring the correct weld patterns are applied
Solution Approach

The Results:

  • VBS display provided the operator with confirmation of correct sequencing
  • Subcomponent work centres started producing and conveying parts in the exact sequence as the mainline
  • Mainline weld robots are provided with the correct program numbers; thus, the correct weld patterns are applied at each mainline work centre

A VBS display located at each mail line subcomponent manual load has started providing operator with a confirmation that the subcomponent is being loaded in the correct sequence. Subcomponents being produced in a required sequence reduced the production time and saved time on the mainline.

This increased OEE, better order scheduling, improved product quality and overall productivity of the plant.


Systems, Tools & Services Expertise

  • Vehicle Broadcast System (VBS) based on MES by Ignition

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