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VFF – Studiu de caz Holistic, extensible, scalable and standard Virtual Factory Framework 11 MAY 2012, Sibiu Gabriela Cândea
VFF – Studiu de caz
Holistic, extensible, scalable and standard Virtual Factory Framework
11 MAY 2012, Sibiu
Gabriela Cândea
Compa is a private company, based in Romania, working mainly for the automotive industry. Compa exports
more than 75% of its products to over 15 countries, on 3 continents.
Compa produces:
• Turbo-charger components
• Windscreen wipers components
• Injector components (NHB, …)
• Steering gears and columns components
• Shock absorbers components
• Hot and cold coiled springs
• Drive shafts
• Stamped parts
• Welded parts
• Air conditioning equipment
• Tools and devices
• Brake equipment and pneumatic brake cylinders
• Die casting parts
Compa is a strong partner for some of the most important international operators of the automotive industry
and is constantly upgrading its business relations in other industries also.
Having acquired the certificates for ISO 9001, TS 16949, ISO 14001, OHSAS 18001 and ISO 17025 Compa is
one of the most reliable Romanian partners.
Compa is a responsible company; it doesn’t work only for its clients and shareholders, but also for the
community development and for a sustainable environment.
Gabriela Cândea
COMPA description
VFF COMPA design and optimization scenario
Gabriela Cândea
COMPA description
VFF COMPA design and optimization scenario
Gabriela Cândea
VFF COMPA Scenario
VFF COMPA design and optimization scenario
Heterogeneous planning tools
Certain planning steps are not optimally supported by tools
Redundant data throughout the activities
Simultaneous/collaborative planning using the same data is not possible
Deviation between simulation models and real factory operation
Limited re-use of experience from previous projects
Limited track of the project management and of the documents
Limited collaboration between functions involved in development
Weaknesses in the current activities
Gabriela Cândea
VFF COMPA design and optimization scenario
Time reduction to design a production line • Reduction of misunderstandings in the design
• Increase of 3D plant models utilization
• Reduction of number of drawings/models
Better assessment of KPIs • Better integration between modeling and simulation
• Increase the collaboration between different functions
Better interoperability between software tools • Reduction of mistakes
• Reduction of redundant manual data entering
• Reduction of errors from files manipulation
Gabriela Cândea
Why VFF?
VFF COMPA design and optimization scenario
Approach
• Optimized planning process based on the Virtual Factory Manager and newly
developed or attached functional modules
• Support for external (from customer) and internal requirements management
• Design and optimize the layout of manufacturing lines
• Evaluate the manufacturing lines using the discrete event simulation based on
the production sequence (from the dynamic side)
• Usage of best practices in order to re-use the knowledge from previous solutions
Gabriela Cândea
VFF COMPA design and optimization scenario
VFF
PEA FMEA tool
iPORTAL
Web portal
GIOVE 3D viewer
WITNESS
Simulation tool
iDS Decission
system
RMW
Dashboard workflow
IPS Simulation
tool
Gabriela Cândea
VFF COMPA Scenario
modules
VFF COMPA design and optimization scenario
Module Acronim Developer Goals
GIOVE - VF GIOVE ITIA 3D viewer, multi user shared
Virtual Environment
IDecissionSupport iDS Ropardo Support for different type of
meetings
iPortal - VF iPortal Ropardo Support for collaborative
work and file mManagement
Interactive Project
System
IPS CEIT Create logistics network of
the factory
Potential failure modes
and Effects Analysis
PEA Ropardo FMEA tool
Requirements
Management Workflow
RMW
Ropardo Check/track the status of
started projects
WITNESS 2007 Witness LMS Commercial Discrete Event
Simulation
Gabriela Cândea
VFF COMPA Scenario modules
VFF COMPA design and optimization scenario
Improvement of planning performance (KPI: i.e. Planning time,
Planning effort)
• Integrated planning framework
• All planning tools use one single factory data model no redundancy
• Re-use of previous solutions (use of best practices )
• Reduction in the variety of technical implementations
Improvement of planning quality (KPI: i.e. Fulfillment of customer
requirements)
• Direct propagation of planning results to all other planning instances
• Increase the effectiveness of APQP and PPAP requirements compliance
• Increase of collaboration and communication between functions involved in
development
• An increase of management for documents/versions control
Gabriela Cândea
Expected benefits from VFF
VFF COMPA design and optimization scenario
Nozzle machining line
&
3 Parts Insert assembly line
Gabriela Cândea
VFF COMPA design and optimization scenario
The sectors and products for which COMPA Use Case is applied are:
- Nozzle assy line
- Nozzle assy – 3 parts insert
Gabriela Cândea
Pilot Case
VFF COMPA design and optimization scenario
Gabriela Cândea
Automatized fabrication facility - Nozzle machining line
Old layout drawing
Final layout drawing
Pilot Case facility
VFF COMPA design and optimization scenario
Gabriela Cândea
Automatized fabrication facility - 3 Parts Insert Assembly Line
Old layout drawing
Final layout drawing
Pilot Case facility
VFF COMPA design and optimization scenario
Gabriela Cândea
12 drawings in 2D
3 simulation models
16 drawings or views on some details in 2D
and/or 3D
10 weeks
Figure about design activity
VFF COMPA design and optimization scenario
Gabriela Cândea
• Each main project change impacts on
2D drawing of the plant in Autocad
Foundation drawing in Autocad
3D model in ProEngineer
Main faced problems
VFF COMPA design and optimization scenario
Activity Influence Definintion of KPI Value AS-IS Value TO-BE
Customer
Requirements
Proposal Time
Time needed to submit
one proposal option to
the potential client
8 days 5 days
Planning
Activities
Design Time Time needed to complete
the detailed design of the
production system
8 days 5 days
Workflow,
Layout
Development
Engineering
time
Time period to carry out
the engineering process - 20% (hours)
Simulation Engineering
time
Time period to carry out
the engineering process - 20% (hours)
Gabriela Cândea
KPI’s values
VFF COMPA design and optimization scenario
ROPARDO S.R.L. Ciprian Cândea (Managing Partner)
Reconstructiei 2A, Sibiu, 550129, RO
Tel. / Fax: +40 269 231037
E-mail: [email protected]
www.ropardo.ro
Gabriela Cândea
Thank you!
VFF project Dr. Marco Sacco (coordonator proiect VFF)
ITIA-CNR Via Bassini 15, Milano, IT
E-mail: [email protected]
www.vff-project.eu
VFF COMPA design and optimization scenario
