Virtual and Phsycial Pre-series Process Verification at Volvo Car Corporation

Sammanfattning: This master thesis was conducted at Volvo Car Corporation, VCC, in Gothenburg within the Manufacturing Engineering department. It is based on the P11-project (the new model S40) where the process verification has been examined and analyzed. The purpose of the thesis is to investigate the reasons behind remaining and new problems at late stages in the development process, as well as possibilities for improvements during pre-series work. Based on this, the objective is to identify and account for problem areas which significantly influence verification activities. Furthermore, recommendations for future in-depth studies, within these specified areas, are presented with the aim to continue the investigation conducted in this thesis. Through the description of the current challenges combined with future, more precise research, the performance of pre-series verification will be enhanced. VCC has recently introduced virtual pre-series at early stages of the verification process in order to enable a more efficient product and process development. The aim is to improve the use of virtual methods, such as advanced simulation tools used to simulate manufacturability, thereby reducing the need for time and cost consuming physical preseries. Achieving improvements in virtual pre-series will allow for front-loading in terms of identifying and solving problems earlier. This thesis focuses on virtual verifications and emphasizes the possibilities for improvements within that area. The investigation was performed as a case study and information was gathered from a database, where process related problems are managed, and through interviews with parties involved in the verification process. Gathering information about basic questions, such as when problems are identified and solved, enabled an observation of the disproportionately large number of problems handled during physical pre-series. Thus, confirming the importance of applying the front-loading theory. By focusing on identifying the reasons for the present situation, this investigation resulted in extensive input providing a broad perspective where a few areas of significance were identified. Four areas with a considerable effect on the quality of the virtual pre-series are emphasized; technical limitations, defective virtual build meetings, poor handling of models, and lack of knowledge transfer. At present, they all contribute to the amount of problems at late stages, thereby implying the need for improvements. The technical limitations are of a tangible nature, directly affecting the performance of simulations, and limiting the handling of problems by postponing verifications to the physical pre-series. The remaining areas refer mainly to aspects regarding working methodology and how it is implemented and perceived by the concerned parties. Partly, the working methodology is affected by immeasurable issues such as confidence in virtual methods, motivation for work, and informal communication.