Large-scale Production Made Perfect

In May 2003, MAG Powertrain started work on the construction of the first of two cylinder block production systems. The customer, General Motors, required turnkey systems, in other words MAG Powertrain had to supply complete systems to handle everything from loading to unloading.

Simultaneous Engineering

To speed up the project development process, the simultaneous engineering (SE) method was used in close cooperation with General Motors. The aim was to simultaneously complete the various phases of the development project and optimize the production process.

In contrast to completing the various development steps sequentially, simultaneous engineering allows independent processes to be carried out in parallel. Thus on the one hand the production process was optimized, while on the other, improvements were made in terms of handling and clamping the workpiece. Evaluating the individual transfer lines using the process optimization system enabled elimination of some of the transfer stations. In one case, it was even possible to eliminate a complete transfer machine, since the operations could be carried out in other transfer machines within the process. Along with the considerable savings in time, one of the main advantages of simultaneous engineering is the increased communication it requires between the project partners and the project teams.

Standardization as a Development Objective

In addition to parallelization of the developments, MAG Powertrain optimized the transfer machine concept by standardizing and integrating processes. As a result, standard units were developed that provided for a distinct separation of the electrics and hydraulics. The advantage of this is that clearly defined interfaces enable a much faster installation of the system on-site at the customer's premises. The left, right and center units were regarded as a complete system and were not dismantled again after undergoing the initial acceptance procedure at MAG Powertrain. This meant that the entire system could be assembled and commissioned very quickly at GM.

New Control Concept for Improved Access

The new control concept allows the right transfer unit to be controlled from the left one, and vice versa. This enables easier access for service and maintenance work since the components that require servicing have been centrally positioned at a single location. And because a controller is no longer required for every machining station, the control concept also helps to reduce costs. Different machining units were grouped to form machining modules, which are controlled by a central controller.

Production Line for the Complete Machining of a 3.9 Liter Cylinder Block, Consisting of two Modules.

Per module:

• OP 10, OP 20, OP 30, OP 40, OP 50: Transfer machines (MAG Powertrain)
• OP 60: Pre-washing machine (Dürr, France)
• OP 70: Bearing cap assembly machine (LSW)
• OP 80A, OP 80B, OP 90, OP 100: Transfer machines (MAG Powertrain)
• OP 110: Transfer machine (MAG Powertrain, U.S.A.)
• OP 120: Honing machine (Gehring, U.S.A.)
• OP 130: Finish washing machine (Dürr, France)
• OP 140: Leak test machine (LSW)
• 2 coordinate measuring machines (Brown&Sharpe)
• 2 washing machines for coordinate measuring machines (Dürr, France)
• all offline gauges, i.e. all quality assurance gauges (Marposs)
• all conveyor systems, including all transport belts and buffers (Dürr, U.S.A.)