Satven’s Digital Systems Cuts Cost, Time-to-market

By APA Bureau:

Satyam Venture Engineering Services Pvt. Ltd. (Satven), the perfect outsourcing solutions partner that addresses the technology and cycle time requirements, caters to the varied and complex design and engineering needs of the automotive industry.Satven with its strong digital manufacturing expertise is offering various services to its automotive customers.
Digital manufacturing technologies enable companies in visualizing the factory scenarios in 3D environment before the actual factory is installed. With descriptive ideas and market dynamics, it has become a challenge to OEMs and the Tier 1 and Tier 2 suppliers to meet the demand so that they can compete in the growing market. Digital manufacturing cuts cost and effort on various fronts. It reduces time-to-market for new product introduction and also the cost involved in installation, physical validation, and the number of iterations.
Established in 2000, skilled human resources, consistent quality, broad knowledge base, strategic partner alliances, domain and subject matter expertise, and strong customer relationships have propelled Satven into higher orbits.
Satven provides comprehensive solutions to the automotive industry that cover a wide range of engineering activities, including Concept Design, Product Design, Value Engineering/ Value Analysis (VA/VE), Dimensional Management, Sourcing, Knowledge-Based Engineering (KBE), Digital Manufacturing Solutions, Mechatronics and MBD solutions for automotive sub-systems, myriad non-linear and linear FEA, full vehicle crash, NVH, durability, Computational Fluid Dynamics (CFD), and Multi-Body Dynamics (MBD).
With over 1,700 engineers working in various locations in India, the US, Europe, Japan and China, Satven is poised to take Indian engineering service industry into the league of Automotive Consulting, and from providing discrete services to complete solutions. Satven is certified for ISO 9001:2008, ISO/IEC 27001:2013, ISO 14001:2015 and BS OHSAS 18001:2007.

Case Studies

Seat Assembly: A study was conducted using digital manufacturing tools with an objective of accommodating the passenger car seat sub-assembly next to the vehicle mainline. The challenge was to come up with the 3D layout concepts considering vehicle variants and volumes with line balance between seat sub-assembly zone and vehicle mainline.
The team came up with multiple concepts of 3D factory layout after brainstorming with the customer, taking into consideration the future plan for the manufacturing plant. With virtual validation of each of the concepts,an optimized 3D factory layout was finalized for sub-assembly and mainline, with optimum number of stations, operators, and robots for seat sub-assembly to vehicle mainline assembly.
Even the sub-assembly zone was well-balanced between operators and robots, and seating assembly zone. The optimized layout had a cycle time well within the mainline cycle time. With newly added sub-assembly zone that is next to mainline, time and cost involved in SCM were highly reduced.
Virtual validation included simulation of robotic assembly, collision tests, reachability/accessibility, ergonomic study and cycle time with line balancing. Digital manufacturing not only saved the costs and process cycle time but also shortened the programme launch eliminating the number of iterations.
Another advantage is that virtually validated robotic assembly coordinates can be off-loaded to robot off-line programming (OLP). This is helpful for shop floor programming activities.

Paint Shop: To establish an optimized paint shop layout using digital manufacturing, a real-time environment of paint process was created virtually with all the required resources such as paint robots, paint atomizers, skids, conveyors, ovens and other related information.
Initial painting process was created, during the project, for the complete paint line and was checked for real-time issues such as interference of robot with plant infrastructure and factory assets.
Based on the virtual process, necessary changes in skid design and the orientation of parts on skid was finalized for process improvement and cycle time optimization. With the help of digital validation, efficient and optimized trajectory of robot was defined which, in turn, reduced the cycle time.
Coordinates of robot can be taken directly for OLP. Optimized layout is thus established for efficient process and utilization of resource.
Making the complete paint process ‘first time right’ on the shop floor was a major time consuming activity.With the help of digital manufacturing proven time was drastically shortened, resources and costs were also optimized in this case.
Weld Cell Layout, Simulation: A weld cell layout design for body-in-white (BIW) assembly streamlines the process and reduces the process cycle time with the help of digital manufacturing process. Initial process planning for BIW panel assembly and concept design for welding fixtures was developed based on the number of panels and stages.
Weld cell design and modelling was developed by introducing the concept design of fixtures, robots, other resources and a virtual simulation was carried out to identify issues related to robot reachability and collision with its coordination tools and factory assets. Based on the study, necessary changes were incorporated in design or process flow.
Satven engineers modify tools such as geo-stations, re-spot stations, load tables, grippers, and gripper stands based on the multiple iterations performed virtually for process optimization. Virtual validation of weld cell layout has significantly reduced the time for proving the design. Therefore, robotic offline programming can be used in the real-time shop floor environment directly.
Satven has successfully carried out the digital manufacturing study and analysis for several other processes including BIW Stamping Process, Plastic Injection Moulding and Assembly processes.

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