Console Setting & Calibration Jigs

Overview

Advanced Industrial Engineeringwere approached and asked to quote for the redesign and supply of ‘console’setting and calibration jigs for a luxury car manufacture assembling vehiclesin the UK.

The customer had an existing set of jigs but approached AdvancedIndustrial Engineering to re-engineer replacement jigs to reduce the weight forthe operator when in use.

The sales team at Advanced Industrial Engineering reviewedthe technical information provided by the customer and submitted a detailedtechnical proposal, including 3D design concept and full cost breakdown.

Background

The customer approached Advanced Industrial Engineering tohelp find a solution to reduce the weight of the existing console setting jigs.The weight reduction would aid the customers assembly operatives when positioningthe setting aid onto the vehicle underbody during the process.

After review of all vendor technical proposals, AdvancedIndustrial Engineering were successfully awarded a contract to supply new jigs.

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Challenges, Constraints and Success

The challenge lay in re-engineering the existing jig designto ensure the current assembly process could be maintained. The customer had statedthat the weight of the jig needed to be reduced where possible to aid thecustomers assembly operatives when loading / unloading the setting aid onto thevehicle underbody on each vehicle.

The redesigned jigs needed to use existing location points onthe vehicle body where possible, achieving this would ensure the existingassembly process could be maintained where possible.  

Success would be seen if the following activities wereachieved and maintained. The safe and effective introduction of new equipmentwith minimal disruption to existing production. The successful adoption of thenew jigs by the maintenance department. The customer continuing to achieve ahigh level of quality and accuracy of vehicle build.

Technical approach / Methodology

The Advanced Industrial Engineering technical proposal wasmade up of the following items:

(1)   Provision of 4-off console bracket setting jigsbased on existing Jig 20102 delivered by Advanced Industrial Engineering

(2)   Provision of 1 off calibration jig & drawingfor the setting jig shown above

The solution included:

•        Full 3D and 2D design, signed off formanufacture by all parties.

•        Factory Acceptance Testing (FAT) at AdvancedIndustrial Engineering’s facility with the customer present.

•        Delivery, installation, and commissioning at thecustomer’s site.

•        On-site operator training following successful SiteAcceptance Test (SAT) sign off by the customer.

•        Full certification and supply of project technicalfile including operator and maintenance instructions, TPM schedule, spare partslist, BOM, DRAs, DFMEA, load test certification, 3D STEP files, GA drawings,and safety guidance.

All equipment would be supplied and certified to the requiredregulatory standards with the correct technical documentation provided.

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Implementation

After being successfully awarded a customer purchase order, AdvancedIndustrial Engineering begin the engineering design process. The team reviewedthe existing equipment, assembly process and new technical proposal. The designdepartment used the new sales concept as a basis for the new design.  

All parties were engaged in the review process of theproposed solution maintaining close customer engagement at every stage up tosign off.  

The new concept design reduced the overall weight of theconsole jig from 9.3kg to ~5.8-6.5kg.

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Location points for securing the jig in position weremaintained where possible or created where required due to the redesign.

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Advanced Industrial Engineering designed and manufactured acalibration jig to ensure that the setting jig could be checked, giving thevehicle manufacture peace of mind that the console position when fitted was ina repeatable position.

Following the design sign off from the customer, AdvancedIndustrial Engineering began to purchase materials and start the manufacturingand assembly.

Factory Acceptance Testing (FAT) was carried out in theworkshop at Advanced Industrial Engineering with the customer present, any changesor upgrades were recorded and implemented prior to shipping to the customer’s site.

Once at the customers site, Advanced Industrial Engineering’sinstallation team managed the full commissioning process, including a finalSite Acceptance Test (SAT) confirming that all fixtures performed as designed.

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Conclusion

In following Advanced Industrial Engineering’s proven processesand procedures, the company was able to re-engineer existing customer equipmentto improve assembly processes.  

The solutions provided, met the requirements outlined by theend user, the delivery and support was performed to the highest level ofquality by the onsite team with timing and budgets maintained.

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