Škoda Auto was looking for a concept that would enable effective management of the tightening tools on assembly lines from various manufacturers. At the same time, it was crucial that the tools could be replaced quickly if they failed. They had to choose an information system that supported implementation of the XML protocol – a standard for the Volkswagen Group, which enables unified communication between the control system and tighteners from different suppliers.
System stability, availability and sustainability in critical operations
This is a critical and high-risk process, where assembly line downtime of any kind can shut down the line completely. Because of this, high demands were placed on the system’s infrastructure, application security, stability, availability and sustainability during the project. The solution includes well-designed fallback procedures and processes that are easy for users to follow. Employees can use them effectively and can quickly switch from standard operation to the emergency strategy when needed. The universal Aimtec DCIx digitalisation platform meets these criteria while also providing a swift and flexible solution that customers can later independently expand, adjust and develop.
Digital assembly control with a focus on quality and control
For each vehicle configuration (trim level), Aimtec DCIx defines the specific operation to be performed and the joint or set of joints to be tightened. It also defines which tightener will perform the operation and the corresponding tightening program. Since vehicles with different trim levels move down the line in a defined sequence, each tightener has its own task queue that precisely matches the vehicle sequence. Aimtec DCIx sends the appropriate programs to individual tighteners in this sequence. The process includes a wide range of real-time control mechanisms. Sensors ensure that each operator is working on the right vehicle, is in the right location, and is performing their assigned operation. Each tightener, as well as each vehicle, is fitted with a sensor.
Rework processes are established for cases where a joint cannot be tightened correctly or at all. Among these is the use of a re-tightening tool operated by a specially trained operator – typically the team coordinator. The operator can perform the process directly on the assembly line without needing to pull the vehicle off to a special station. The other possibility is to work based on the Four-Eyes Principle: one worker tightens joints manually with a torque wrench while a second checks it and confirms it is correct. Both approaches make use of mobile devices from Zebra Technologies. Thanks to Aimtec DCIx, joint repairs are digitalised and much faster. The goal is always to get the vehicle to the end of the assembly line at the highest quality level and complete all required operations on it. An HMI panel displays an overview – a list of vehicles on the line and the status of individual joints: tightened or untightened. The system continually informs workers regarding tightening outcomes in individual segments as well as the end of the line. The quality department thus has the whole process under control.
A quick journey from prototype to deployment
This project kicked off in June 2023 with a process analysis and installation of Aimtec DCIx. The first functional prototype was produced within just four months; it was then tested successfully at Aimtec. This was followed by prototyping in cooperation with the Škoda Auto team right at their plant, transferring know-how throughout the departments – manufacturing, technology, maintenance and IT – and the final step, key integrations into 40 services and 15 internal systems. Live operation began in June 2024. After this successful start, the solution is gradually being deployed at other work centres as well – welding and paint shops and assembly lines in Mladá Boleslav and Kvasiny.
Aimtec
With over 29 years in business, we have more than 6,000 completed projects behind us worldwide. We help you to digitalise and automate production, logistics, planning and the supply chain into one functional whole that lets your transformation bring you a real benefit – for one plant or your whole global network. Quickly, logically and sustainably.
We unite experts in several digitalisation areas under one roof. Their specialities range from SAP to industrial digitalisation, automation, advanced planning, EDI and hardware. Our customers include DENSO, Magna, Lear Corporation and SCHERDEL.
Media contact:
Petra Troblová
Key Account Marketing Manager
petra.troblova@aimtecglobal.com
+420 724 284 141
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