In this case study, we will show you how FIRAC, a SNEF Group company specializing in the design and integration of robotics and automation, used the 3D simulation software, Visual Components to automate a process of manual subassembly in an automobile manufacturing plant in France.
Key benefits:
- Consideration of time-consuming external factors and their expected effect
- Visualized and validated proposals are communicated more effectively
Automating a Manual Subassembly Process in an Automotive Manufacturing Plant
FiRAC, a SNEF Group company, is a leading company that specializes in the design and integration of robotics and automation , particularly in the streamlining of industrial equipment and processes with intelligent technical solutions.
It often relies on Visual Components' simulation technology to help show its customers how much more efficient it can make its processes if it adopts a greater level of automation.
This was the case with one of their projects with the PSA Group , which produces automobiles from renowned global brands such as Peugeot and Citroën. The company was looking for a way to improve quality while keeping its cycle times consistent with a specific screw tightening task on the assembly line .
Using production simulation technology , FiRAC was able to provide an efficient solution that struck the perfect balance between cost and productivity. Find out how…
The project: automate screw tightening by making cycle times more reliable
In automobile manufacturing, production times are vital and so is quality.
Groupe PSA 's automobile manufacturing plant , France, was looking to optimize the tightening of front wheel bolts to speed up cycle times and improve production quality .
FiRAC used simulation technology from Visual Components to demonstrate how the process could be automated .
Tightening screws at the factory was previously done manually . Therefore, in addition to creating an automated solution, cycle times needed to remain fast and consistent to ensure overall productivity goals were met.
Concretely, this subassembly requires the tightening of five screws for the front wheels of the vehicle, four of the screws (M6-8 Nm) which are on the front face and one (M8-20 Nm) on the rear face of the panel . This assembly was previously performed by one operator over four shifts, however, the skill level of that individual largely dictated the performance cycle times, which ranged from 30 to 60 seconds . The inconsistency of this task often made it difficult to stay in line with the main whole.
“Any second lost during this process means lost productivity on the main line, given that a car is produced approximately every 60 seconds”
Quickly test scenarios to find the best way to automate the process
FiRAC used Visual Components 3D manufacturing simulation software to conduct a variety of scenarios to help PSA Group automate the process. The scenarios included using only one robot, two robots facing the product and two robots facing each other, among others .
The first scenario tested included a single robot performing the screw tightening task , which it completed in just over a minute.
The second scenario included simulating two robots side by side, one tightening the four M6 screws and the second tightening the M8 screw . This cycle time was clocked at 54.8 seconds.
The third final scenario was designed with two robots, but in a face-to-face configuration . This turned out to be the most optimal solution and the fastest simulation of the process, completing the task in less than 53 seconds.
It is the simulation that was chosen by the PSA Group, because it proved to be the ideal compromise between cost and performance.
“Visual Components is so versatile that it was very easy to implement the different configurations and visualize their effect on cycle time. Once we found the best simulation, we were able to edit a video of the process and provide quantified, visual reasoning to support our final solution. »
Visual Components 3D simulation software: help with the design and sale of the project
FiRAC's competitors who were also consulted for this project insisted that the process could be automated using a single robot.
However, these competing companies showed no visualization to really demonstrate how this could be done quickly and efficiently .
In addition to the visual representation of the process, Visual Components allowed FiRAC to take into account multiple time-consuming external factors and anticipate their effect . Thus, the travel time of the AGV, the tightening time of the screws, and even the processing time of the camera were taken into account very early on, thus providing a solid technical background to the proposal.
It was one of the great advantages of using Visual Components software that the visualized and validated proposal could be effectively communicated to Groupe PSA .
Visual Components: cycle time optimization software
Visual Components also helped FiRAC solve optimization issues with the robots so they could better understand and design the best way to achieve the customer's desired cycle times.
For example, in the simulation where both robots were positioned on the same side, one robot would have to wait several seconds for the other to complete its task before it could begin its respective task. In some simulations, the two robots would collide, further delaying the process.
This is part of the reason why the two robots in face-to-face positioning proved to be the most effective solution.
“With the simulation, it was clearly demonstrated why it was impossible to adapt the process within the required cycle time with a single robot. The client was really impressed with the visual implementation of the process – and this is how FiRAC gained the competitive advantage to win this project. »
3D simulation software used after the pre-sales phase
Visual Components' role did not stop after FiRAC won the project.
After project award, FiRAC continued to use technology to validate the mechanical design of all elements to ensure accessibility, proper clearance and factory layout.
The solution was implemented in approximately 6 months, with FiRAC spending a few months on site to test and fully integrate the solution into the workshop.
Use 3D simulation in the pre-sales phase to convince your customers
You too, like FiRAC, can benefit from the advantages of Visual Components 3D simulation software in your project response phases. You will save time on design and visually communicate your project to the client for a quick understanding of the latter.
You are interested ? Contact us for a free demonstration.
Project details
Project timeline | October 2018: Receipt of the RFQ |
October 2018 (2 weeks, not spent 100% on the simulation): Pre-study | |
November 2018 – May 2019: Technical reframing and negotiations | |
May 2019: Rewarded project | |
July 2019: Acceptance of the design | |
September 2019: Factory acceptance testing | |
October 2019: Commissioning / On-site acceptance test | |
December 2019: End of ramp-up, final acceptance | |
Industry | Automotive – Production |
Project | Automate a manual subassembly process in an automotive manufacturing plant |
Customer | PSA Group |
Location | Sochaux, France |
Solutions integrator | FiRAC |
Contact | Corentin Monnot, project manager at FiRAC |
