Automotive Battery Parts Manufacturing Case Study Highlights
Challenge
- An automotive part manufacturer needed a late-cycle product design update on their cell contacting system which required the development of an entirely new process and production line, posing a substantial risk of delaying the vehicle launch.
- This required simultaneous engineering to optimize the new process, while developing the overall line.
- The new line had numerous product variants and recipes and movements between stations, requiring thorough testing and refinement.
- The manufacturer experienced delays in the delivery of critical materials, impacting the power-on schedule.
Solution
- Simulated the line with virtual commissioning, resolving potential issues before physical implementation.
- Conducted product development and line development at the same time, using simultaneous engineering.
- Integrated Illuminate™ Manufacturing Intelligence to track overall equipment effectiveness (OEE) and performance metrics.
Results
- Virtual commissioning saved over six weeks of time, allowing factory acceptance testing (FAT) to take place on its original date.
- Developing the product and assembly line in parallel significantly reduced the project timeline.
- A digital twin enabled the production of 400 virtual parts for more robust testing, ensuring an efficient ramp-up and saving critical expenses the customer would otherwise have spent on expensive prototypes.
Company
Automotive Parts Manufacturer
Industry
Automotive Industry
Region
Global
Customer
A prominent automotive parts manufacturer, headquartered in Europe. That specializes in the production of components including electric vehicle (EV) batteries, electric drive units, and fuel cells.
Challenge
Overcoming Unexpected Safety Requirements and Logistic Complexities
An automotive parts manufacturer faced significant challenges while developing a battery parts line. While they requested a new feature to increase the battery system’s safety, it posed a substantial hurdle. They would need a new production step for the dispensing process step, since it was introduced late in the product launch timeline. This threatened to delay the project and impact consumers.
The line itself also had complicated logistics, adding to the project’s complexity. The logistic concept involved multiple back-and-forth movements between stations, making it essential to thoroughly test and refine these processes. A tight timeline and the need for precise coordination between project components further intensified these challenges.
Solution
Innovative Solutions with Digital Twins and Virtual Commissioning
To address these challenges, experts at ATS Industrial Automation implemented a comprehensive solution leveraging digital twin technology and virtual commissioning. The digital twin could create a virtual replica of the system, enabling the team to test system logic and material handling flows integration without physical prototypes, while a parallel team focused on in-depth process development efforts. This approach facilitated simultaneous engineering, where real integration work and software development occurred at the same time.
Harnessing the power of the digital twin, a global team of ATS experts from Germany, Canada, and the United States seamlessly collaborated around the clock to ensure continuous progress. The virtual commissioning process particularly optimized the complex logistics of the assembly line. By simulating the entire line, the team could identify, test, and resolve potential issues before the physical build happened.
Through this global collaboration, the programmers developed solutions that were integrated into the main system twin. Additionally, ATS used its Illuminate™ Manufacturing Intelligence to track overall equipment effectiveness (OEE).
Even with a tight timeline, virtual commissioning allowed ATS to continuously test the system and apply updates while the physical line was being built and shipped.
Results
Achieving Timely Results with Virtual Commissioning
This approach—including concurrent engineering—saved over six weeks of project delays, allowing factory acceptance testing to occur on its original date. While the physical line was being built and shipped, the digital twin ran for an additional month, incorporating feedback from the FAT.
Integrating Illuminate™ within the digital twin was another key factor in the project’s success. Illuminate™ tracked OEE metrics, providing a clear visualization of how the line was performing. This prevented delays during physical commissioning and ensured the system met all target metrics. The result was an efficient assembly line ready for immediate ramp-up upon arrival, ultimately delivering a high-quality solution for the automotive parts manufacturer.
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