1 FIAT sponsored competition for the best final thesis in year 2016

1 FIAT sponsored competition for the best final thesis in year 2016

FIAT sponsored competition for the best final thesis in year 2016
Topics
1. Fiat Auto Poland SA
Numer Priorytet
Advanced primer process management vs
energy reduction
1.1
Zarządzanie zaawansowanym procesem
podkładu a redukcja zużycia energii
Cooling water optimization for welding line
1.2
Optymalizacja wody chłodzącej dla linii
zgrzewalniczej
Process optimization for welding vs electric
power compsuntion
Uwagi
Analysis of e-coat dryer operation parameters in
Paint Shop A and B and defining the
assumptions to reduce the consumption of
energy factors.
Analiza parametrów pracy suszarek katoforezy
Lakierni A i B i określenie założeń dla
zmniejszenia zużycia czynników energetycznych.
Optimizing parameters of the operation of the
spot-welder cooling water system for robotized
spot-welding lines of Body Shop A and B
Optymalizacja parametrów pracy sieci wody
chłodzącej zgrzewarek dla zrobotyzowanych
linii zgrzewalniczych Spawalni A i B.
Improvement of the cosΦ power coefficient for
the Body Shop. Analysis of the eclectic network
as well as general and spot-welder reception
and the definition of technical interventions for
the compensation of reactive power.
1.3
Optymalizacja procesu dla zgrzewania a
zużycie energii elektrycznej
1.4
Energy stream optimization for Body, GA and
Paint Shop
Optymalizacja Energy Stream dla jednostek
produkcyjnych Spawalni, Montażu i Lakierni
Spare parts optimization
1.5
Optymalizacja części zamiennych
Poprawa współczynnika mocy cosΦ dla Spawalni
- analiza sieci eklektycznej oraz odbiorów
ogólnych i zgrzewarkowych i zdefiniowania
interwencji technicznych dla kompensacji mocy
biernej.
Elaboration of the Energy Stream Map for the
Assembly Shop, Paint Shop and Body Shop
Opracowanie Energy Stream Map dla
jednostek produkcyjnych Montażu, Lakierni i
Spawalni.
Optimizing the process of supplying spare parts
for the maintenance in order to reduce the
warehousing period – reduction of the working
capital
Optymalizacja procesu zaopatrzenia w części
zamienne dla utrzymania ruchu
w celu skrócenia okresu magazynowania –
obniżenie kapitału obrotowego.
1
Visual inspection monitoring vs glass glueing
1.6
Monitoring kontroli wizualnej a wklejanie szyb
Visual Inspection for closures quality
1.7
1.8
1.9
Kontrola wizualna jakości części ruchomych
1.12
Zastosowanie systemów wizyjnych, po wklejeniu
szyby przód/tył przez roboty Durr linia D dla
weryfikacji luzów i profili.
Application of visualization systems to check
flush and gap of doors and the engine hood on
the Final Line tapparellas
Visual Inspection for the control of the wheel
fastening screws
Zastosowanie systemów wizyjnych, do
weryfikacji luzów i profili drzwi i maski przód na
Tapparellach Final Line.
Application of the visualization system for the
control of the wheel fastening screws
Zastosowanie systemu wizyjnego do kontroli
śrub mocujących koła
Visual Inspection for the control of the
blockages on the door hangers
Zastosowanie systemu wizyjnego do kontroli
śrub mocujących koła
Application of the visualization system for the
control of blockages on the door hangers
Zastosowanie systemu wizyjnego do kontroli
blokad na zawieszkach drzwi
Zastosowanie systemu wizyjnego do kontroli
blokad na zawieszkach drzwi
Analysis of phenomena taking place in screw
connections depending on the coefficients of
friction, strength, covering and the structure of
the screw connection elements. Optimum choice
of the torque and angle based on the example
of the rear beam rear shock absorber of Lancia,
rear wheel hub of ‘500’, engine suspension on
the gearbox side of ‘500’ etc.
Optimizing the choice of the torque and angle
1.10
Application of visualization systems, after
mounting the front/rear window by the Durr
robots on line D to check flush and gap
Optymalizacja doboru momentu obrotowego i
kąta dokręcania
System of signalling the collection of tools
Analiza zjawisk zachodzących w połączeniach
śrubowych w zależności od współczynników
tarcia, wytrzymałości, pokrycia i struktury
elementów występujących w połączeniu
śrubowym. Optymalny dobór momentu
dokręcenia i kąta dokręcenia na przykładzie
amortyzatora tylnego belki tylnej Lancia, piasty
koła tylnego „500”, zawieszenia silnika od strony
skrzyni biegów „500”.
Elimination of human errors by introducing the
system of signalling the collection of tools,
devices, wrenches in the car assembly process.
Eliminacja błędów ludzkich poprzez
wprowadzenie systemu sygnalizacji pobierania
narzędzi, przyrządów, kluczy w procesie
montażu samochodów.
Analyzing the process of cold attachment of
Optimization of the process of attachment with
elements with two-side adhesive tapes.
two-side adhesive tapes
Phenomena taking place in the process of
System sygnalizacji pobierania narzędzi
1.13
2
Optymalizacja procesu klejenia przy pomocy
taśm dwustronnie przylepnych
attaching door mouldings and side spoilers.
Methods of error elimination and adhesion
optimization.
Automatic interoperational reloading system in
the assembly line
Analiza procesu klejenia na zimno elementów za
pomocą taśm dwustronnie przylepnych.
Zjawiska zachodzące w procesie klejenia listew
bocznych, nakładek progu (minigonna). Metody
eliminacji błędów i optymalizacji przyczepności.
The project of automatic interoperational
reloading system to eliminate the crane for one
of the selected units:
- CNG gas cylinder unit (28 l, 50 l),
- drive unit from the UMC line to roller conveyor
A
- rear suspension unit on subassembly stations
(Milllenium building 8A)
1.14
Automatyczny system przeładunku
międzyoperacyjnego w linii montażu
Optimization of subassembly workstations
1.15
Optymalizacja stanowisk pracy podmontaży
Analysis of the impact of contamination in the
process of filling the braking system
1.16
Analiza wpływu zanieczyszczeń w procesie
napełniania układu hamulcowego
Top coat deposition optimization
Projekt automatycznego systemu przeładunku
międzyoperacyjnego w celu eliminacji suwnicy
dla jednego z wybranych zespołów:
- zespołu butli gazu CNG (28 l, 50 l),
- zespołu napędowego z linii UMC na Rullierę A,
- zespołu zawieszenia tylnego na stanowiskach
podmontażu (Milllenium, JP montażu obiekt nr
8A).
Analysis of the workstation organization of
various subassemblies in order to minimize the
cost of subassembly of details (Muri, Mura,
Muda) and of their transportation to the
assembly line stations.
Analiza organizacja stanowisk podmontaży
różnych, w celu zminimalizowania kosztów
podmontażu detali (Muri, Mura, Muda) i ich
transportu na stanowiska linii montażu
The influence of the contamination of the
braking system components on the degree of
reaching the vaccum and, consequently,
incorrect filling and travel of the brake pedal.
Wpływ zanieczyszczenia komponentów układu
hamulcowego na stopień osiągania próżni i w
konsekwencji nieprawidłowe napełnienie i skok
pedału hamulca
Reduction of enamel consumption by optimizing
the spraying and reducing the overspray.
1.17
Optymalizacja zużycia emalii
Energy recovery int the Paint Shop
1.18
Odzyskiwanie ciepła na Lakierni
Redukcja zużycia emalii przez optymalizację
natrysku i zmniejszenie over spray
The project of the system for recovering heat
lost in the painting processes.
3
ICT optimization vs palnt management
1.19
1.20
Optymalizacja ICT a zarządzanie zakładem
Waste disposal in the paint shop processes
Utylizacja odpadów w procesach lakierniczych
Elimination of quality defects in the paint shop
processes
1.21
Eliminacja wad jakościowych w procesach
lakierniczych
Optimization of the control of air-conditioning
units
1.22
Optymalizacja sterowanie centralami
klimatyzacyjnymi
Poka yoke for human error reduction
Projekt systemu odzyskiwania ciepła traconego
w procesach lakierniczych.
The IT system for the maintenance including:
-management of the equipment documentation
/ archiving
-planning of electrical measurements
-facilitating the management of internal
warehousing
-taking over the SAP functions which are not
easy to manage, e.g. the history of inspections
and breakdowns, in order to monitor the MTBF
and MTTR indicators.
System informatyczny dla działu utrzymania
ruchu obejmujący:
-zarządzanie dokumentacją urządzeń
/archiwizacja
-planowanie pomiarów elektrycznych
-ułatwianie zarządzanie gospodarka
magazynową wewnętrzną
-przejęcie funkcji z SAP-a które są nie wygodne
do obsługi np. historia przeglądów i awarii,
celem monitorowania wskaźników MTBF i MTTR
The disposal of solid organic waste by the
biotechnological method.
Utylizacja stałych odpadów organicznych
metodą biotechnologiczną.
Elimination of the quality defect – stains
(different shade) on the paint coat for enamel
695 Grigio, 323 Cipria.
Eliminacja wady jakościowej – plamy (inny
odcień) na powłoce lakierniczej dla emalii 695
Grigio, 323 Cipria
The project of the system for the control of
paint cabin air-conditioning units to reduce
energy consumption.
Projekt systemu sterowania centralami
klimatyzacyjnymi kabin lakierniczych celem
redukcji zużycia czynników energetycznych.
Elaboration and execution of the system
ensuring the elimination of human errors in
logistic areas (sequences, kittings).
1.23
1.24
Poka yoke dla redukcji błędów ludzkich
Opracowanie i wykonanie systemu
gwarantującego eliminację błędów ludzkich w
obszarach logistycznych (sekwencje, kittingi)
Optimization logistics proces
Elaboration of the IT system for simulating
logistic workflows in FAP that allows to define
the optimum workflow.
Optymalizacja procesu logistycznego
4
Containers logistics optimization
1.25
1.26
Optymalizacja logistyki pojemników
Zarządzanie obrotem pojemników – wdrożenie
systemu identyfikacji pojemnika na każdym
etapie przepływu.
Preparation of the logistic process simulation in
order to optimize it using the tools of lean
Optimization of logistic processes for the wheel manufacturing (VSM, Kanban) in the wheel
group assembly
group assembly area (Millenium)
Optymalizacja procesów logistycznych w
procesie montażu grupy koła
Analysis of the resources necessary for the
logistic management
1.27
Opracowanie systemu informatycznego do
symulacji przepływów logistycznych w FAP
pozwalającego na określenie optymalnego
przepływu.
Management of container circulation –
implementing the system of container
identification at every stage of the workflow.
Analiza zasobów niezbędnych do obsługi
logistycznej
Przygotowanie symulacji procesu logistycznego
celem jego optymalizacji z wykorzystaniem
narzędzi lean manufacturing (VSM, Kanban) na
obszarze montażu grupy koła
Elaboration of the tool using ACCESS to define
the resources needed for the logistic
management of the plant (material supply) on
the basis of consumption and master data of the
details.
Opracowanie narzędzia z wykorzystaniem prog.
ACCESS do określenia zasobów potrzebnych do
obsługi logistycznej zakładu (zasilanie
materiałowe) na bazie zużycia oraz anagrafiki
detali
2. Teksid Iron Poland Sp. z o.o.
Numer Priorytet
2.1
2.2
Programma di computer che permette di
valutare in modo automatico il livello di
sferoidizzazione della ghisa in base
all'immagine della struttura
Program komputerowy pozwalający ocenić
automatycznie stopień sferoidyzacji żeliwa na
podstawie obrazu struktury
Confronto delle esigenze e metodi di
valutazione relativi al livello di
sferoidizzazione secondo le norme
internazionali e le esigenze specifiche dei
protuttori auto.
5
Porównanie wymagań i metod oceny
dotyczące poziomu sferoidyzacji wg norm
międzynarodowych i specyficznych wymagań
producentów samochodów.
Impatto della forma del grafite e livello di
sferoidizzazione sulle proprieta' di resistenza
dei getti di ghisa.
2.3
2.4
2.5
2.6
Wpływ postaci grafitu i stopnia sferoidyzacji
na własności wytrzymałościowe odlewów
żeliwnych.
Impatto dei tipi dei difetti e loro dimensione
sulle proprieta' e funzionalita' dei getti di
ghisa - elaborazione dei criteri di
accettabilita'.
Wpływ rodzajów wad i ich wielkości na
własności i funkcjonalność odlewów
żeliwnych - opracowanie kryteriów
dopuszczalności.
Esigenze per l'ottenimento delle proprieta'
richiesta per la ghisa perlitica GH 90-52-05 AS
(AS CAST).
Warunki dla uzyskania wymaganych
własności żeliwa perlitycznego GH 90-52-05
AS (AS CAST).
Impatto della temperatura di
sovrariscaldamento e tempo di mantenimento
della ghisa sferoidale sul livello di
grafitizzazione (numero dei nuclei).
Wpływ temperatury przegrzania i czasu
przetrzymania żeliwa sferoidalnego na
stopień grafityzacji (ilość zarodków).
Dross sui getti di ghisa sferoidale, cause di
genereazione e metodi per prevenire la
presenza dei difetti.
2.7
Dross w odlewach z żeliwa sferoidalnego,
przyczyny powstawania i sposoby
zapobiegania wystąpienia wady.
Impatto del boro sulla struttura e proprieta'
della ghisa sferoidale.
2.8
Wpływ boru na strukturę i własności żeliwa
sferoidalnego.
6
3. Magneti Marelli Poland Sp. z o.o.
Numer
Priorytet
Intelligent control sequential injection in the
plastics processing industry.
3.1
Inteligentne sterowanie wtryskiem
sekwencyjnym w procesie przetwórstwa
tworzyw sztucznych.
The use of computer-aided design in plastics
processing.
3.2
Wykorzystanie komputerowego wspomagania
projektowania w przetwórstwie tworzyw
sztucznych.
Uwagi
The use of pressure and temperature sensors
to create a signal loop. Transmission of
information about the course of the injection
process in real time directly from the socket of
the injection mold.
Wykorzystanie czujników temperatury i
ciśnienia do tworzenia sygnałów pętli
sprzężenia zwrotnego. Przekazywanie informacji
o przebiegu procesu wtrysku w czasie
rzeczywistym bezpośrednio z gniazda formy
wtryskowej.
Use injection simulation software for the design
and startup of injection molds.
Wykorzystanie programów symulacji wtrysku
przy projektowaniu i uruchamianiu form
wtryskowych.
The aim is to design automation of some
exhaust elements in NX environment (reduction
of the time required to design)
3.3
Automation in design process of exhaust
systems in NX environment (Unigraphisc)
3.4
Automatic design of 3D models of exhaust pipes The aim is to ensure adequate flow of gas in
- to ensure constant/unchangable pipes section the pipe through the design proces
3.5
Reduction of NVAA based on the WCM and
ErgoUas methods.
3.6
3.7
3.8
3.9
3.10
Analysis of dashboard assembly process,
describe NVAA and presentation of reduction
NVAA by WCM and ErgoUAS methods.
Analysis of impurities on the bumpers during
Reduction of inpurities on the painted bumpers, automatic painting, prepare methods to reduce
increase of FTQ
amount of impurities. Increase FTQ for painted
bumpers
Use of DOE method to describe the correlation
Influence of injection moulding parameters for
between injection parameters and product
selected quality defects.
quality.
Automation of parameters changes of milling
machine tank B420 in correlation with the input
temperature of the tank after the blow
Automation of parameters changes on milling
moulding
machine in correlation with temperature of
product at the end of blow moulding process
Automatyzacja zmian parametrów maszyny
frezującej zbiornika B420 w zależności od
temeratury wejściowej zbiornika po rozdmuchu
Development of process flow based on VSM for
logistics families within the plant.
Process flow based on VSM metrics
Opracowanie procesu przepływu na podstawie
VSM dla rodzin logistycznych w całym zakładzie
Tagauchi/ANOVA as advanced tools in problem Lack of the weatability on the bumpers related
solving process
to the parameters washing/flaming/painting
7
3.11
3.12
3.13
3.14
Analisys the result method of control paint
coatings in variable painting parameters
Impact parameters painting on the visual and
funcionality paint caoats.
Impact of injection process parameters on the
Injection process parameters and alternation of
properties of Polipropylene based on injection
polipropylene proprieties
dashboard 312 MCA
Microscopic analysis of impuritis in the coatings
Microscopic analisys painting coats
of paint in order to eliminate the aesthetic
quality defects bumpers
Analysis of occupational risk in accordance with
Analysis of occupational risk in accordance with
WCM methodology (Risk assessment, Risk
WCM methodology
prediction)
3.15
Reducing the set-up time on the welding shock
absorber's line using the SMED Methodology
Reducing the set-up time on the welding shock
absorber's line using the SMED Methodology
3.16
Maintenance Professional tools as measures of
improving indicators of the availability of
machines and equipment.
Application Maintenance Professional tools for
improving indicators of the availability of
machines and equipment.
3.17
Develop a PM's methodology for optimizing the
efficiency of test machines
Develop a PM's methodology for optimizing the
efficiency of test machines
3.18
Non destructive test for welding penetration
Non destructive test for welding penetration
3.19
Reduction NVAA on production line with usage
3d scanning in reference to machining line UKL
Reduction NVAA on production line with usage
3d scanning in reference to machining line UKL
Application robot for pick up not ordered cast
irons or cast aluminum parts from containers
and loading it into production line.
Optimisation cycle time on machining centers
by using cad cam simulations (for example Top
Solid).
Application robot for pick up not ordered cast
irons or cast aluminum parts from containers
and loading it into production line.
Optimisation cycle time on machining centers
by using cad cam simulations (for example Top
Solid).
Rendering usually are no accurate because of
no enough accurate source description. Good
source definiotin help for very accurate and
photorealistic renderings
Prototyping of plastic components with
roughness is dificcult to get similar Ra what is
on the mould or injected component.
Technology what allow to make accurate
rougness on free from small and complex
shapes is welcome
The tasks involve: a) preparation of the FEM
numerical model for simple geometry and
acoustic analysis, b) preparation of a stand for
noise measurements, c) making noise
measurements for simple geometry, d)
comparison of experimental and numerical
results
The tasts involve: a) preparation of thermomechanical FEM model of vibration welding
process, including geometry and materials
characterization, b) simulation of vibration
welding process for 2D and 3D geometries
3.20
3.21
3.22
Plug-in - Physical accurate source definition
3.23
Roughnes prototyping on free-form plastic
components
3.24
Noise analysis using FEM simulations
3.25
Numerical modeling and analysis of vibration
welding process
8
3.26
3.27
3.28
3.29
3.30
3.31
3.32
3.33
3.34
The tasts involve: a) experimental
determination of material characteristics of
foams, b) preparation of proper numerical
Research on properties and numerical modeling
material models based on experimental results,
of foam materials
c) preparation of FEM models of the
experimental test, including material calibration,
d) simulation and comparison of results
The aim of the study is to analyze the influence
of various process variables metallization taking
into account the geometry and position of the
Influence of the technological parameters
metallized surface in the vacuum chamber, for
equipment for metallization in a high vacuum
the quality, the thickness and durability of the
on quality metallized surface of the molding.
obtained layer. A comparison of the
experimental results with computer simulations
of the metallization process.
The aim of the study is to analyze the effect of
processing parameters of the injection molding
The influence of process parameters and the
(ie., The injection temperature, injection speed,
geometry of the injection molding multi-PMMA mold temperature, cooling time, etc.) as well
cohesive strength properties.
the connections geometry of the subsequent
injection of PMMA in to the mold cavity, for the
quality and cohesive strength properties.
The aim of the study is to analyze the direction
of the flow of material and the order of
Comparative analysis of the type and position
injection and processing parameters for the
of the point of injection and the mass flow in
amount of deformation and dimensional
the material moldings multicomponent PMMA / changes multilayer injection moldings produced
PC to minimize deformation.
by multicomponent injection molding. The
analysis involves the use of various types and
points of injection.
Student's task will be get familiarized with
working principle of PTFE membranes;
determine experimentally the characteristics of
Humidity diffusion of goretex membranes.
air flow through membrane; investigate
experimentally the moisture diffustion through
the membrane and identify its diffusion model.
The main task is to prepare proper calibration
of electronic components in thermal simulation
Calibration of thermal simulation model of
software (CFD) with real products comparison.
electronic components.
Calibration will be prepared in increasing
complexity of models.
Process of polyamide material for injection of
aesthetical frames
Types of plasticizing systems and their impact
on the material type being processed
Lean vs WCM – production management
methodologies of yesterday, today and
tomorrow
9
4. Fiat Powertain Technologies Poland Sp. z o.o.
Numer
Priorytet
Uwagi
4.1
Machine parameters monitoring for diagnostics
4.2
Robots cooperating in the automotive industry
4.3
Advanced vision system for quality control
4.4
Robotic tightening stations on continuous
movement lines
Automation and visualization of diagnostics
and monitoring of the grade of wear of
machines components on the basis of
changing parameters like: cycle time,
temperature, pressure, Energy consumption
etc.
The cooperating robots used in the
automotive industry .
The modern vision systems used for quality
control of the product.
The robotic tightening stations on
continuous movement lines.
4.5
Analysis of implemented changes associated
with machining processes of cylinder block as
the requirements of the Euro 6
Analysis of the changes in machining
processes of the cylinder block in the
context of changes according to the Euro 6.
4.6
Advanced lighting systems in halls and in
workplaces management
The modern lighting systems in halls and in
workplaces.
4.7
Spare parts proliferation, cost of materials vs
cost of management
The spare parts proliferation, the cost of
materials vs the cost of management.
4.8
Advanced internal logistics vs condition
management
4.9
Optimization of AGV trolleys: studies of
computer system for optimized management
4.10
Ergonomic harness assembly on the engine
The conditions to be met by the perfect
internal logistics
Optimization of AGV trolleys; studies of
computer system which can manage
trolleys.
The ergonomic harness assembly on the
engine.
4.11
Additive Manufacturing: comparative study
between automotive conventional product vs
optimized AM
Additive Manufacturing process: a
comparative study between an automotive
conventional product vs an optimized AM
(cost, process cycle, energy)
4.12
To use the WCM tools in order to optimize
process safety in production lines.
The continuous improvement of safety
standards in the WCM system
4.13
The project is associated with the change of
the deep-drilling in the oil channels of the
crankshaft journals and crancpin of the
crankshaft. The implementation of new
technologies is related to the installation of
MQL system whose task was to cool tools with
oil mist. With this technology can be speed up
several times the process of deep drilling and
finally to eliminate one machine.
Production of the world class WCM in
machining processes, in the automotive
industry.
10
4.14
The work includes WCM tools to improve
working conditions at assembly workstations,
to optimise the station parameters and to
reduce production losses. It has been presented
the project to eliminate leaks from the
camshaft drive cover during the leak tests, and
the second project about the reduction of
Production of the world class WCM in
micro-stoppages during the assembly of
machining processes, in the automotive
bearings to the motor housing. Some tools have
industry.
been used to solve the above-mentioned
problems as: Major Kaizen and experimental
design (DoE). Some optimal methods about the
feeding of production line with the parts have
been presented: frontal feeding and using the
sets, and consequently it can increase the
flexibility of the entire assembly line.
4.15
To use the WCM tools in order to eliminate the
"bottleneck" in the machining process on the
cylinder head SDE.
Increase the line efficiency within the Focus
Improvement in the WCM process.
4.16
To use the WCM tools in order to optimize
maintenance processes within the programmed
maintenance.
Rationalisation of the work in the
Maintenance Dep. in the exemplary
automotive production company, based on
the WCM methodology
11