3/15/2018

DM-WC-DESIGN-I &II (PS)

Digital Manufacturing & Work-cell Design:
Process and Design of
Production System (Automotive)
By

Abdo Al-Zaher | Ph.D., P.Eng,|

Process & Design Simulation/ Virtual Analysis
Vehicle Systems NA Automation Execution
2018/03/15

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Outline
 PS- Overview/
SW Layout, Project Set-up ( Why PS is needed ?)
 Mfg &Assembly Automotive / Challenges of the production line.
 Digitization the production line : What knowledge needed prior to DM ?
 Manufacturing Eng./ Working as a member of a Global Team /Automotive Project
Case study: Slide 12
 Process and design of manufacturing work-cell (Automotive Assembly)
 Building Resources (modeling) and the automation process Operation
 SOO,LB, CEE, Operation and Safety DCS
 Simulation Outputs: Process & Design stage
References:
‒ My work with the Automotive production as a member to GMNA Suppliers group
(NAVO),
‒ Siemens at the Hannover Messe 2015
‒ Siemens, automation and digitalization 2015

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Robotech Canada Consulting Inc

ROBOTECH CANADA CONSULTING INC
906 Elmgate Cres., Windsor, Ontario, N9H 2E3
Mobile: 519- 563-8519
E-mail: | robotech.ca@gmail.com|
Processing & Design Simulation/ Virtual Analysis of Systems and
Robotics work-cell for Automotive Assembly. |www.robotechcanada.com|

Abdo Al-Zaher
Abdo Al-Zaher | Ph.D., P.Eng, |
President

• He hold a PhD in Industrial and Manufacturing Engineering Systems from the University of
Windsor, MSc in Mechanical and Manufacturing Engineering from the University of Manitoba.
BSc Upgrade from McMaster University. 1991.
• 20+ years of comprehensive experience in Process & Design Simulation/ Virtual Analysis
(Vehicle Systems NA Automation Execution GM, World Tech Ctr.).
• Also working as a senior researcher and sessional instructor for graduate courses at the
University of Windsor.
• He is also the CEO of Robotech Canada Consulting Inc., Engineering Manager and design lead
for more than 18 years in the automotive industry, participating in design and execution of more
than 120 projects (BIW) and dozens of framing systems in North America, Mexico, Spain, and
Germany for GM.

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Virtual analysis & simulation

Virtual analysis & simulation for the process and design of robotic work-cells
systems, include the following:

o Create and develop Virtual Model of the production systems to optimize systems
capability.
o Developing system layout, including robotic equipment, for optimal performance.
o Preform engineering analysis on robotics systems to improve duty-life cycle and
power consumption of power drivers.
o Create and develop robotics OLP template to be use for current and future programs.
o Performing robot payload analysis to determine the appropriate robot settings.
o Validating robot tooling and die designs and determining system performance.
o Providing design suggestions for robot smart placement, tooling and dress package.
o Generating documentation and reports for systems operation and maintenance.
o Following up on design and integration in the plants for system calibration.

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DM-WC-DESIGN-I &II (PS)

DIGITAL MANUFACTURING & WORK-CELL DESIGN:

(REQUIRED SIEMENS: PS. V13.1A)
 Digital Manufacturing & work-cell design introduced in two parts .

The first part is introduction of the manufacturing and assemblies

processes of production lines, including the construction of robotics work cell;
building the manufacturing process, Material flow. Signals, logic block . The
second part the true Digital manufacturing systems using process simulate
and NX process simulate v13.1a Software, allowing mechanical/electrical and
manufacturing engineers to create the complete manufacturing process of
production systems in a virtual environment, including: tooling equipment of
the assembly line, process and operation, facility layout, ergonomics and
resources. Real engineering project will be introduced.
In the first Part I:
Engineers

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DM-WC-DESIGN-I &II (PS): set-up

FUTURE

Stage I Stage II

SERVER
USERS

SEC-01 SEC-02
 Lib Data
 PROJECTS DATA

(JT and
COJT
Files)
4 sys-
projects

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Project Template: Data Resources

JT is the only standard industry format
for PS

Product
Tooling and
equipment data
• Resource lib
• Exciting or new

Process & Resources

• Equipment
• Operation

WF: USERS

Engineering Studies
• Programing
• PLC
• Work-cell

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Final assembly production systems?

 2.5 – 3.5 million sq feet (280,000 vehicles annually)

 400-600 robots ▼-
 400-600 PLC’s
 20-25 miles of conveyors ▼-
 800-1200 vehicles in /system ▼-
 1000-1200 operators/shift ▼-
 62 vehicles/hour output ▲+
 HPV. ▼-
GM Fairfax assembly plant Kansas city USA
 45 -60 Systems needed to make the
car

Metal forming

Bottleneck Gate WC

CT: 3 .75 – 6.0 sec

I II III IV

Digital Manufacturing Process and design of Production system (Automotive-2016)

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Challenges of the production systems?

1 shift production: 16x60x8=7680

12 – CT:5.0
MF becomes 16 – CT:3.75 run video Modular
20 – CT:3.0
• More efficient Assembly
• Less lead time

1 sec=6000 part per day

Metal forming
 New variant, more customization (▲) for free
 Throughput: --- new process (▲) ?
 Energy consumption (▼) by optimizing motion

 Enterprise moving to Digitization of

Production, Smart production line with
embedded sensors
 Using LPT to gain 25% of SPM

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Doors Assembly production line

Sat 55

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Cycle Time & RV-Duty Cycle

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FOL Production Systems PS: Case study

Production PRESS
Systems
VISION SYS

ROBOT-02

OILER

CONVYEOR

ROBOT-01

GANTRY SYS

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Design Concept: production System Level I

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Design Concept: production System Level II

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Final Design: detailed design

Create discussion of
throughput, product
variety and flexibility
of the equipment

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Developing Mfg., process: SOO

WS2 WS3 WS4 WS5

OP20 OP30 OP40 OP50

Product Variety
 720 Job P/H ---------- (720x22.5)+ 816200 P/D
 How many Part per vehicle needed
 65-70 P/V (280.000 Vehicle per Year

 HOW MAY PRODUCTION LINE NEEDED ?

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Developing Mfg., process: SOO

Flow
Manufacturing
1 2
inspection
STA 05

STA 06 STA 07 STA 08 STA 09 STA 10 STA 50 STA 00

STA 60
Gantry Sys Feed Conv Oiler Vision Sys Load Conv Press OP

Final assembly
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Developing Mfg., process: SOO

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Layout of the Mfg. system.

Sequence of operation for each station to
o Execute the processes
o Layout of the systems
o VR and DM simulation System/sub-sys
o All deliverables to built the production sys.

Final Assem
Cell 1 Cell 2

STA 80
R04 (W)
R12 Compo
STA 20

STA 40

STA 60
STA 45
STA 15

R08 Compo

R11(W)
STA 30 R07 (W)
R06 (W)
STA 10

R03 Compo STA 70

STA 00
STA 65
R01 (W)

STA 50

R09 (m/h)

R10 (W)

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Developing Mfg., process: SOO

System/sub-sys
Different processes can
be discussed
Cell 1 Cell 2
1.1a STA05: Operator load 3 parts + weld STA50: Operator load 3 parts + 4 ws

STA10: stud welding station STA60: Stud station

STA15: staging station STA65: staging station

STA20: Sealer station STA70: Welding station 20 ws

32 weld spots
1 weld nut STA30: Welding station + weld 24 weld spots
4 stud weld STA40: Stud station)
6 stud weld
200 mm sealer STA45: staging station

1 2 3 4 5 6 7 8
inspection
STA 05 STA 10 STA 15 STA 20 STA 30 STA40 STA 45
STA 00

Mirage Station STA 70 STA 80

1 2 3
Final assembly
STA 50 STA 60 STA 65

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Developing Mfg., process: SOO

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Developing Mfg., process: SOO

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Kinematics: Gantry Sys Virtual data

7000 mm

3600 mm
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Kinematics: Gantry Sys Virtual data

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Robot Selection Criteria: Application& load

o What are the robots selection criteria ?.
 Application,
 Loads depends on the application and parts
 Future use development & flexibility

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Robotics-vision systems: Cameras setups

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Robotics-vision systems: Calibration grid

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Robotics Programing: Path structure

Pounce Home
Drop 1
Drop 2
Pick 1 Drop 3
Pick 2 Drop 4
Pick 3 Drop 5
Pick 4
Pick 5 P2: Pounce
P1: Home
P5: Ddep
P2: Papp
P5: Pdep P7: Dapp

P4: Pk P6: Pclr P4: Dp

PART PART

Process 1
Process 2
Process 3
Weld
Weld-Ped

Dispense

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WC: setting up DCS User Element's

What is DCS ?
 DCS (Dual Check
Safety) is used to restrict
robots space and
working envelope..

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WC: setting up DCS parameters.

Use PS to
set DCS as
input to TP

2 pt Diagonal to
define zone

DCS position monitoring can be used for redefining the robot’s restricted envelope or dynamic limitation of the
robot envelope (DLD). Date completed: 2016/11/17

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Developing Mfg., process: SOO

WS2 WS3 WS4 WS5

OP20 OP30 OP40 OP50

Adding Adding
new new
systems systems
More More
robust robust

All student need to identify the issues with current systems;

How to add flexibility to the systems to handle different styles for the same
family of product

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Adding 7th axis to the robot: High speed

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Robotics Programing: EOL SYSTEMS

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Ergonomics: motion set-up

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