[Case sharing] Using 3d printing, Mercedes-Benz factory fixture design cost is reduced by 99%, efficiency is increased by 6 times

Background : Since the birth of the world's first steam engine, the German Mercedes-Benz has been with the automotive industry for more than 200 years. The production and manufacturing of automobiles is still the top priority. The design, development, production and final assembly of each accessory component determine the value of a car brand and the quality of the vehicle. As the largest overseas factory of Mercedes-Benz in Germany, Beijing Benz has introduced intelligent and on-demand manufacturing technology into the production process of the whole vehicle through innovation and improvement of fixtures, becoming an indispensable element in high-quality automobile production lines.

Mercedes-Benz's largest overseas factory - Beijing Benz has an annual output of 400,000

Beijing Benz was established in August 2005. It is a joint investment between Beijing Automotive Co., Ltd. and Daimler AG and Daimler Greater China Investment Co., Ltd., integrating R&D, engine and vehicle production, sales and after-sales service. The Sino-German joint venture is also the first Mercedes-Benz engine engine manufacturing plant outside Germany. It has grown from an initial design of 100,000 vehicles to an actual annual production of 400,000. It is the most advanced world class in China. Manufacturing companies, mainly producing Mercedes-Benz C-class, E-class, GLK SUV and GLC SUV four cars, are introducing GLA series, with the mission of "expanding driving space and improving quality of life", Beijing Benz is going to China Users provide advanced products and services that are consistent with Mercedes-Benz global standards.

As a world-class automobile manufacturing plant, Beijing Benz wants to shorten the development cycle and improve the assembly efficiency of the production line. Each production line requires a large number of fixtures to assist the assembly workers in assembly. At the same time, various inspection tools and special calipers are required to ensure assembly. Accuracy, and the optimization and innovation of fixtures has become a very important part of Beijing Benz's manufacturing process. Under the specifications and standards of intelligent manufacturing, Beijing Benz will complete a large number of innovations for specific production links, including Optimization and improvement of fixtures.

Beijing Benz Challenge: Accelerate R&D, Reduce Cost, Improve Efficiency

Smart factory and intelligent manufacturing in Beijing Benz is mainly embodied in informationization and flexibility, in the face of rapid response to information, to solve problems encountered in the actual production process, in the past a large number of fixtures need machining and casting, the need to find the external The supplier then carries out the program discussion, quotation, price comparison, etc., and finally carries out the procurement. After the delivery, the test is carried out on the production line. However, in most cases, it needs to be modified several times, the efficiency is very low, and most fixtures use metal materials. It is also necessary to cover the surface of the metal fixture with a layer of anti-scratch protection layer. The period from communication to final delivery is very long, which will seriously slow down the production line of the production line.

The current three major product platforms of Beijing Benz include the front-drive plant, the rear-drive plant and the engine plant. Nowadays, the electric vehicle factory is being built, and the research and development and pre-testing of electric vehicles are carried out at the same time. The fixtures for manufacturing standardized batteries are the production links. In the very important part, according to the output of 20,000 pieces, normal labor takes 3 months to complete, and it takes only 2 weeks to optimize the fixtures under the same manpower workload, if through external suppliers. Designing fixtures and performing battery processing requires a cost of 500,000 RMB. In the end, with the cooperation of all the improvement departments of the manufacturing engineering department, only 4,500 yuan is required, the time period is shortened, and the manufacturing cost is reduced. The cost reduction of 99% and the efficiency increase of 6 times) are promoted and implemented by this 30-person innovation team. Although everyone plays different functions in the project, they are responsible for the innovation and optimization of Beijing Benz.

Introducing 3D printing to assist Beijing Benz's innovation improvement and optimization

As the most advanced intelligent manufacturing leader in the world, in 2016, Beijing Benz improved the assembly efficiency of the production line, modified the fixtures, and promoted business innovation in the direction of automation and leanness. All employees of Beijing Benz Manufacturing Engineering improved. The Innovation Department was established to optimize fixtures and innovations for all production lines in Beijing Benz, introducing Stratays F370 3D printers for design verification and tooling development.