Overview
To date, a clear hierarchic structure dominates automotive manufacturing assuring a 100% delivery of components and systems just in time and just in sequence.
However, new challenges emerge, such as:
- a steep increase in modularisation and interdisciplinary technologies;
- market pressure for variability and flexibility to customers;
- cost pressure demanding a reduction of stocks on the supply side;
- a highly flexible mastering of global production and delivery, which will mean a rapid development of an efficient 'networked' production scheme.
This called for a determined step forward in motor vehicle technology combined with a dynamic planning process involving the full supply chain. In order to break with the traditional hierarchic manufacturing, revolutionary concurrent elements were introduced that reduce stocks and allow last minute configuration of new products in higher variations and quality and at lower costs.
The prime objective of AC-DC was to develop a concept that radically enhances automotive
manufacturing in order to achieve the high level of responsiveness required for a 5-day car process, according to customer specifications, with the development and introduction of individual and highly reactive planning loops in the supply chain.
The efficiency of this future system was validated realistically by considering the emerging step-change in component technology (technology convergence of 'Mechatronics' for customer neutral modules of high parameterisation).
Coordinated by Continental Automotive Systems (Dr. Wolfgang Menzel -Vice President Logistics Automotive) the consortium of major European car manufacturers, suppliers, research institutions, and academia addressed a vehicle system that promises maximum impact and reward regarding the transferability to other parts of the vehicle and that could be achieved within the four years duration of the project.
From a technical point of view, the developed highly mechatronic automotive chassis modules support a late customisation of order-neutral modules towards costumer-specific requirements. Derived from this novel automotive chassis technology there is plenty of potential for even new drive-trains, electrical propulsion, and new wheel systems. The technologies tackled by AC-DC enhanced existing safety functions and increase driving comfort options. Technical progress in intelligent software and sensor-actuator technology combined in customer-neutral mechatronic chassis modules pave the way to the next generation of automotive chassis, which needs to be taken into account by new automotive production processes.
Furthermore, AC-DC developed the requisite 'dynamic supply chain collaboration concept' that promotes the conventional automotive terms of delivery to a highly reactive 5-day-capable' system that cuts down inventories in the supply network. Importantly, AC-DC maintained a 100% guarantee of delivery as an uncompromised constraint. Leaving hierarchic production concepts behind by building on multiple planning loops the dynamic supply network management is an ideal test case for the integration of both the requisite high-tech module technology and the appropriate process configuration features.
Funding
Results
The rationale of the AC-DC project was to achieve a step change improvement in the automotive supply chain efficiency and collaboration regarding new challenges, such as:
- steep increase in modularisation;
- market pressure for variability and flexibility to customers;
- cost pressure demands a reduction of stocks on the supply side;
- highly flexible mastering of global production and delivery.
This called for the rapid development of an efficient 'networked' production scheme that replaced the traditional hierarchy step-by-step.
The AC-DC database was maintained and since the development of a rapid industry recovery tool is now being pursued - which depends on new and close-to-market data sets - the focus was placed on carefully updating and maintaining the project's glossary.
VDI/VDE-IT was responsible for the task of financial management, which comprised the collection of the management reports of all partners. It included the technical support for the administration of the internal and external website.
The vehicle simulation was enhanced by the modelling of the EPS actuator, including the signals voltage, current, steering wheel angle, steering wheel torque, and forces in the steering rack. Simulation results including an advanced electrical network have been portrayed. The algorithms for the add-on functionalities have been developed further including road and manoeuvre identification.
The construction of the rear axle demonstrator was done at Volkswagen, including the ZF components rear-axle-differential and electric stabiliser. The hardware in the loop test bench at ZF has been restructured and the new components electric power steering and electric roll control have been included.
Early prototypes of key critical elements of the software environment were developed. First early prototype test with end-users were accomplished and the development of full prototypes of the software environment was started.
Appropriated mechanisms were developed based on the open source ebXML messaging service which provides a secure and reliable transport protocol to the ebXML Architecture. This service was enlarged to allow communication protocols involving several business messages and multi-cast or even broadcast communications. To assure a reliable and secure data transfer in the AC-DC network the communication protocols were implemented in a prototype.
Value stream mapping (VSM) and design (VSD) for the use c