In the previous blog we discussed about BIW CAD Engineering services that we offer. Refer the following link to read the blog part-1 (Click here).
This is Part-2 of the blog and it will focus on deliverable & uses of teardown of BIW (Body in White) & DIW (Door in White) assembly & detailed T-BOM (Teardown- Bill of Material) generation.
Teardown of BIW & DIW:
Teardown is a process of dis-assembling child assemblies and child components from their parent assembly in a strategic manner. Along the process, critical information is mapped which is further utilized for following purposes:
1. Should costing
2. Input for design engineer
3. Supply chain complexity study
4. Production engineering inputs
5. Reference for focused cost reduction projects (VA/VE)
All teardown activities are cumbersome and require huge amount of resources (time & money). Try to remember the last teardown activity you were involved with and the challenges you faced.
1. Too much of data, 20% relevant & 80% scrap.
2. Non-structured random data, mostly images.
3. Accessibility issues & multiple copies of the same thing.
4. Difficulty in searching for any specific parts, be it image, technical info or even the hierarchy level.
There must be many more, now in order to solve these issues, we targeted them one by one and devised a detailed solution with following attributes:
1. Strategic, to the point.
2. Less time and money consuming
3. Highly accurate
4. Provides structured data and ease of accessing them
5. Finding any data of any vehicle from any activity with or without portal/software dependency.
Case Study (B-Pillar of BIW Structure)
The teardown workflow and process with which we claim to achieve the above attributes is explained through a small case study where a B-Pillar BIW structure was cut from the vehicle and torn down up to the last level.
Scope of the activity:
1. Cut the B-Pillar LH portion from the BIW & generate Teardown BOM.
2. Map parameters such as hierarchy, weight, quantity, thickness, material, manufacturing process, Weld spots, 3 Views on grid sheet, Box Dimension, Coating thickness and technical comments.
3. Map the profile of the section and make a detailed section in CAD
The above workflow is specific to this activity, in case of a full vehicle teardown the activity starts with Bay design, photo booth set-up etc. The workflow and the workshop is entirely customizable and flexible to changes in case of a deviation in the activity.
1. Consolidated BOM
The consolidated BOM includes all the parameters on one sheet with all parts, sub-assemblies and assemblies. The list of parameters can vary from 10 to 100 based on the depth of analysis & data mapping required.
The image below shows few of the parameters that we map to create Bill of material of the teardown vehicle.
2. Hierarchy wise Individual Input Sheet and High-Quality view images on grid sheet
Every folder has very high quality 4 images of every part with input sheet with same parameters as explained above, but specific to the single part.
The images are taken on grid sheet with 100X100 grid size to measure dimensions later, if required by the user.
3. 2D CAD with thickness and profile details of the B-Pillar section.
B Pillar section study was also conducted to understand the thickness details of the panel and profile. The data is provided to client in 2D CAD format (1:1 scale) for further study.
4. Detailed teardown images:
The above deliverables are provided to the client with a handbook which explains the data search methodology, usage of the types of data provided and other studies that can be performed using the output of this activity.
In the Part-3 of the blog, data analytics, thickness map, mounting philosophy and weld map will be explained in detail