Geometry Assurance Integration in Current Development process at Volvo GTT

CONCEPT

VERIFICATION

PRODUCTION

Variation Simulation & Visualization

Agenda

Introduction

Current situation of Geometry assurance at Powertrain GTT

Why Powertrain GTT is looking for new Geometry Assurance process?

Variation Simulation on a case study and its benefits

Suggested Geometry Assurance process for Powertrain GTT

Benefits of implementing the suggested Geometry Assurance process

Challenges

How to choose a robust solution?

How to do right from beginning?

How to predict variation?

How to reduce

geometrical variation?

How to reduce cost from idea to market?

How to smooth the way from

design to production?

Major contributors of variation?

How to improve product quality?

Here is the solution……

CONCEPT

VERIFICATION

PRODUCTION

Variation Simulation

Geometry Assurance

Case Study

Pipe

Bracket

Cylinder head

Parts in Assembly

Geometrical Variation in X,Y,Z ?

Geometrical Variation in X,Y,Z

Locating Scheme

Central Concept of Geometry Assurance

X Y

Z

A1A2

A3B1

B2c1

Locating Schemes

Stability Analysis

Variation analysis of point MP in X direction

Variation analysis of point MP in Y direction

Variation analysis of point MP in Z direction

Contribution analysis of point MP in X direction

Contribution analysis of point MP in Y direction

Contribution of point MP in Z direction

Actual design of Bracket & Pipe

Tolerances acting in Pipe in actual design

Major contributor : Tolerance acting point MP = 2mm

New design suggestion and tolerances

Assumed Tolerance acting at point MP = 1mm

Comparison of variations of point MP in X direction

Actual Design Suggested Design

Comparison of variations of point MP in Y direction

Actual Design Suggested Design

Comparison of variations of point MP in Z direction

Actual Design Suggested Design

Comparison of contribution analysis of point MP in X direction

Actual Design Suggested Design

Comparison of Contribution analysis of point MP in Y direction

Actual Design Suggested Design

Comparison of Contribution analysis of point MP in Z direction

Actual Design Suggested Design

Geometry Assurance

CONCEPT

VERIFICATION

PRODUCTION

Current Phase of Geometry Assurance at Powertrain Volvo GTT

Current phase of Geometry Assurance in powertrain

GTT

No systematic process for Geometry Assurance

Primary focus on Functional requirements

Bottom-up approach in tolerances

No flow of data from production

Experience matters Tools like

CTOL, Excel, RD&T are used

RD&T used by three

engineers

Worst Case and RSS are mostly used

Monte Carlo used on critical

requirements

Why Powertrain Volvo GTT is looking for Geometry Assurance implementation?

Why Volvo Powertrain

needs Geometry

Assurance?

Awareness about

tolerances

Shorten lead time from project to product

Reduce physical

prototypes

Share common database

Improve supplier

interaction

Involve manufacturing

engineer in concept phase

Attain functional

requirements with max

quality

To choose robust solutions

To choose manufacturing

processes virtually before

production

Suggested Geometry Assurance process for Powertrain Volvo GTT

GSU (Geometry System Developer)

System design

Geometry demands

Tolerance calculation

GAE (Geometry Assurance Engineer)

Geometry pre-planning

Early verification

Launch

GE (Geometry Engineer)

Running production

Reduce spread

Preventive maintenance

CONCEPT

VERIFICATION

PRODUCTIONGeometry Assurance

Database

SQM(Supplier Quality Management

Quality of incoming material

Supplier connection

SQM(Supplier Quality Management)

Quality of incoming material

Supplier connection

SQM(Supplier Quality Management)

Quality of incoming material

Supplier connection

Suggested process map for Powertrain Volvo GTT concluded from interviews

CONCEPT

INDUSTRALISATION

PRODUCTION

NEWCurrent

Gap Study for Powertrain Volvo GTT in Concept phase

Supplier interference & freeze

Production data input

Systematic process

Geometry System Developer

Variation Simulation

Cross functional team

NEWCurrent

Gap Study for Powertrain Volvo GTT in verification phase

Virtual Verification of prototypes

Virtual matching & trimming

Geometry Assurance Engineer

Supplier Quality Engineer

Selection of manufacturing processes virtually

NEWCurrent

Gap Study for Powertrain Volvo GTT in production phase

Inspection database

Root cause analysis

Data measurement

Database

Geometry Engineer

Benefits of implementing Geometry Assurance

Benefits

Robust solutions

Having control over process

Problems can be fixed in

design

Less adjustments in production

Having cross functional team helps in taking good decisions

Reduce redoing of

things

Defining locators and requirement breakdown

Supplier relation

gets stronger

“Engineers

solves problems;

Geniuses

prevent them”

-Albert Einstein

Solve PROBLEMS like an ENGINEER

PREVENT them to happen like a GENIUS

Meet Mr. Variation Simulation here……

https://youtu.be/_0dUasDsgMY?list=PLlxxiuTZVDyKVPRfZPphnCH3E6T9ikaKm

Thank u